ProcessStandard Flexo (PSF) — White Paper

Executive Summary

The PSF is a newly introduced process standard by Fogra for flexographic (flexo) printing in the packaging and finishing sector. It provides a structured approach for print-shops to demonstrate high-quality, colour-accurate and process-controlled flexo production. Certification under PSF offers proof of capability to clients, reduces trials and waste, simplifies colour communication, and supports more efficient workflows.

This white paper outlines the background, objectives, structure, certification process, benefits, implementation considerations and recommendations for adoption of PSF.

1. Background & Rationale

Flexographic printing is widely used in the packaging industry, capable of printing on a variety of substrates—films, plastics, corrugated board, labels, etc. (W)
However, despite its versatility, flexo printing presents specific challenges when it comes to achieving consistent colour reproduction and process stability across jobs, substrates, ink­spectra, lighting conditions and client expectations.

For clients and printers alike, colour mismatches, process variability, and inefficient setups lead to increased waste, re-runs, manual corrections, slower time-to-market and greater cost. In recognition of these issues, Fogra has developed PSF to bring a scientifically grounded, industry-practical standard for flexo printing.

As stated by Fogra:

“Flexo printing faces major challenges when it comes to colour accuracy. The solution: Fogra’s process standard.” (fogra.org)
The standard is positioned as part of Fogra’s broader certification ecosystem alongside PSO (ProcessStandard Offset) and PSD (ProcessStandard Digital) for other print-technology segments. (fogra.org)

2. Objectives and Scope of PSF

Goals of PSF

• Establish clearly defined guidelines and tolerances for flexo printing, aligned with state-of-the-art practices. (fogra.org)
• Provide a measurable “fingerprint” reference for each printing condition, rather than prescribing fixed targets for all circumstances. (fogra.org)
• Enable consistent reproduction of the fingerprint through production print runs, ensuring colour accuracy, reproducibility and client trust. (fogra.org)
• Simplify colour communication between print-shops and clients (and repro houses) by anchoring on a standardised reference. (FlexoTech)
• Reduce setup time, waste, error rates and ultimately cost and environmental impact by avoiding trial-and-error methods. (fogra.org)

Scope

• The standard is specific to flexographic printing processes (print-shops using flexo presses).
• It applies to one “printing condition” (i.e., a specific combination of press, substrate, ink, process) which can be certified. (fogra.org)
• Additional modules/options exist: e.g., spot colours, in-house or external repro (“repro” option) included in PSF. (fogra.org)
• The standard covers both the fingerprint generation (test form) and subsequent production print run for verification. (fogra.org)

3. Key Components & Methodology

3.1 The Fingerprint

• The print‐shop prints a dedicated test form (provided by Fogra) under defined conditions to generate the “fingerprint” of that printing condition. (fogra.org)
• This fingerprint becomes the reference for production. Rather than specifying absolute target values for all colourimetric parameters, PSF uses the fingerprint + tolerances. (fogra.org)
• During production, the print-shop aims to reproduce the fingerprint as closely as possible and stay within the tolerances. (fogra.org)

3.2 Production Print Run and Sample Submission

• After one to a few weeks of normal production, a short production print run is performed and defined samples are taken from the printed roll. (fogra.org)
• Samples are sent to Fogra’s laboratory for assessment. (fogra.org)
• Evaluation includes whether the fingerprint tolerances were met (solid tone colours, tone value increases) and characterisation of colour gamut, smallest printing tone value etc. (fogra.org)

3.3 Optional Modules

• Spot colour option: One to three spot colours may be selected, included as solids in the test form; target library values must be met. (fogra.org)
• Repro option: In-house or external repro must ensure printed tone values follow a smooth progression; contract proof produced (including the Fogra MediaWedge) to simulate the fingerprint; particular attention to smallest printing tone value; suitable ICC profile required. (fogra.org)

3.4 Certification & Validity

• Upon successful evaluation, the print-shop receives a certificate (valid for two years) and can use a digital quality seal for marketing purposes. (fogra.org)
• Certified companies are listed in Fogra’s PSF database, making them searchable by quality-conscious clients. (fogra.org)

4. Benefits & Value Proposition

For print-shops:

• Demonstrates clear proof of high-quality, colour-reliable flexo production (competitive differentiation). (fogra.org)
• Fewer manual trials, fewer corrections, less waste and less downtime – hence lower cost and improved margins. (fogra.org)
• Simplified communication with clients about expected results, reducing back-and-forth and approval delays. (fogra.org)
• Builds trust with clients by backing production with an independent certification from a reputable body.
• Supports sustainability: less waste equals reduced environmental impact. (fogra.org)

For clients (brand owners, converters, agencies):

• Easier selection of qualified print-shops (via PSF-certified list) reducing risk of non-conforming jobs. (fogra.org)
• Greater assurance that required colour specifications will be met more reliably.
• Potential savings in time (less need for press-checks, manual adjustments) and waste.

For the industry:

• Moves flexo printing toward greater standardisation, reproducibility and professionalism.
• Facilitates easier downstream chain coordination (prepress → print → finishing → client) via a common reference framework.
• Raises the overall quality bar for packaging print production.

5. Implementation Considerations

When a print-shop considers adopting PSF, the following should be taken into account:

5.1 Pre-requisites

• The print-shop must define a stable printing condition (press, substrate, ink, anilox, etc). The test form/fingerprint is tied to that condition.
• Good instrumentation and measurement capability (e.g., spectrophotometer, colour measurement equipment).
• A stable process environment: consistent substrate batches, ink quality, press settings, etc.
• Internal quality control procedures for monitoring the production run to ensure consistency.

5.2 Operational Integration

• Incorporate the printing of the fingerprint test form into routine workflows.
• Schedule the production print run and sampling after initial printings.
• Train staff to understand the tolerances, measurement processes, how to interpret deviations, corrective actions.
• Integrate data collection (e.g., print run metrics, measurement logs) to track compliance over time.

5.3 Cost & Time Considerations

• The certification has a cost (Fogra lists e.g. €1,470 for member / €2,100 regular for the basic certificate) according to their published price. (fogra.org)
• Additional cost for spot colour module, repro option. (fogra.org)
• Time: initial setup, printing test form, production run, sampling, evaluation – may take several weeks.
• Maintenance: Since certificate valid for two years, print-shop must maintain the process and may be re-certified or monitored.

5.4 Challenges & Risk Management

• If process conditions change (substrate supplier change, ink change, press rebuild) the fingerprint may no longer be valid; re-fingerprint may be required.
• For flexible packaging, substrate variability and press conditions may be more unstable than sheet-fed offset; this must be accounted for.
• Managing spot colours and special inks may increase complexity.
• Print-shops must ensure internal measurement reliability and consistency (instrument calibration, staff training etc).

5.5 Adoption Strategy

• Begin with one stable printing condition (press + substrate + ink) to achieve PSF certification; expand to other conditions later.
• Use certification as marketing tool: promote PSF-certified status to clients, include digital seal, list in Fogra database.
• Use PSF certification as a driver internally for process improvement (reduce variation, monitor key metrics).
• Client communication: Pre-define expectations, incorporate PSF baseline into contracts or job specifications for colour.

6. Relationship with Other Standards

• PSF is analogous to ProcessStandard Offset (PSO) (for offset printing) and ProcessStandard Digital (PSD) (for digital print). Fogra’s certification portfolio encompasses all three. (fogra.org)
• While PSO and ISO 12647 series provide reference target values and workflows for sheet-fed and web offset, PSF adopts a fingerprint approach suited to the flexibility of flexo production. (fogra.org)
• The standardisation of print production workflows (e.g., measurement, profiling, proofing, substrate characterization) is governed by documents like ISO 12647, ISO 13655, etc. (ISO)
• Therefore, PSF should be seen as complementary: it doesn’t replace ISO standards but builds on them in the flexo space.

7. Case Example (Industry Adoption)

One recent announcement states that a German label-printer, Thüringer Papierwarenfabrik, has become the “world’s first” to achieve PSF certification. (FlexoTech)
They cite benefits such as improved workflow, strengthened quality standards, and enhanced customer satisfaction.
This illustrates that PSF is now entering real-world adoption, offering early-mover advantages for certified print-shops.

8. Recommendations for Packaging Print Companies

• Evaluate readiness: Assess your current process stability, measurement capability, substrate/ink consistency, and staff competence.
• Select pilot printing condition: Choose a currently stable press + substrate + ink combination most representative of your major business.
• Engage with Fogra early: Contact Fogra to discuss which modules, printing conditions, timelines apply for your certification. (fogra.org)
• Train your team: Ensure operators, prepress, colour-management staff understand the standard, fingerprint concept, analysis of results.
• Integrate quality monitoring: Implement measurement logs, variance tracking, corrective actions so you can maintain compliance beyond just certification.
• Use certification as a marketing differentiator: Update your website, proposals, client presentations to feature your PSF-certified status.
• Plan for scale: After initial certification, consider expanding to other printing conditions (substrates, inks) as part of continuous improvement.
• Measure ROI: Track metrics like job re-runs, waste reduction, time to approval, customer complaints, and compare pre- vs post-certification.
• Align with sustainability goals: Use PSF’s waste-reduction and process-efficiency benefits to support environmental-responsibility strategies.

9. Summary & Outlook

The ProcessStandard Flexo (PSF) represents an important step forward in standardising flexographic print production, enabling higher colour consistency, improved process control, and stronger customer confidence in packaging print workflows. With a scientifically grounded methodology and industry-relevant structure, PSF offers print-shops a clear path to certification and clients a reliable way to select qualified service providers.

In an era where packaging quality, brand consistency, and sustainability are increasingly critical, adopting PSF can be a strategic differentiator. As more printers become certified, it is reasonable to expect PSF to become a recognised benchmark in the flexo packaging supply chain.

10. References

• Fogra. “ProcessStandard Flexo (PSF)”. Web page. (fogra.org)
• Fogra. “Topics in Packaging & Print Finishing”. Web page. (fogra.org)
• FlexoTechMag. “World first as Thüringer gains new Fogra flexo standard”. Nov 2025. (FlexoTech)
• ISO-Committee. “Guidelines for using print production standards v2 Jan 2024”. (ISO)