Oy vay. This has been posted about again and again for visa exempt individuals. She does NOT need the PR card to board the plane if she is visa exempt. Think about it for a second. When she goes to the ticket agent to get her boarding pass all they will look at is her ability to enter Canada without a visa. The passport reader will indicate biometric information (name, dob, etc.), previous entry and exit dates, will detect fraudulant passports, etc. Depending on the country it may also have information relevant to criminality, etc. If you are a wanted terrorist travelling on your own passport and it is scanned, it will alert the agent to contact their security as they won't want you to board the plane (obviously). There is also a system between several countries that sends inbound information about travellers so they know who is coming. So in your case, if they send the information to Canada and CBSA sees your wife is a PR, what is the problem? A PR is a PR with or without the damn card as long as they meet the eligibility requirements. Sorry if I sound frustrated but this question gets answered at least once a week. I know that there is a lot of confusion about it EVERYWHERE but this is how it works.