In October, 1910 the United States Tobacco Journal reports demand has exceeded supply and the Mecca cigarettes have shortages. This is right about the time I would expect the cards to be starting to enter the market.
It is purely speculative, but this rather than cost may have been the reason the silver borders were quickly abandoned, if it was taking too long to get the extra fancy work done on the cards and there was an active shortage in the market, the need for more expensive premiums clearly wasn't there and slowing down distribution wouldn't be advisable.
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