Same-day turnaround available

Simulated Process
Color Separation

Achieve photo-realistic prints on dark garments using advanced halftone techniques. Our simulated process separations blend spot colors to reproduce stunning gradients and full-color imagery on any fabric color.

Same-day delivery
From $25 per design
PSD · Print-ready files
Send Your Artwork >Ask a Question
Simulated process color separation example — photo-realistic print on dark shirt

Simulated Process — photo-realistic separation on dark garment

The Technique

What Is Simulated Process Color Separation?

Simulated process color separation is the gold standard for photo-realistic screen printing on dark garments. Instead of using four transparent CMYK inks that rely on a white substrate, simulated process uses 6–10 opaque spot-colored inks printed as halftone dots that optically mix to create thousands of apparent colors.

The technique starts with a white underbase — a foundation layer that blocks the dark fabric — then builds color on top using carefully calibrated halftone screens at precise angles. The result is vibrant, photo-realistic imagery that simply cannot be achieved with standard CMYK process printing on dark apparel.

This is the preferred method used by professional print shops for band merchandise, artist prints, premium fashion graphics, and any design with complex gradients, skin tones, or photographic detail.

  • Works on black, dark, and any colored garment
  • 6–10 spot color channels per design
  • White underbase layer for vibrancy and opacity
  • Custom LPI: 35–65 lines per inch based on press type
  • Screen angles offset per channel to eliminate moiré
  • Elliptical, round, or square halftone dots available
  • PANTONE® ink color matching included
Simulated process color separation file in Photoshop — layered channels for screen printing

Layered PSD file — each ink channel separated and halftoned

How It Works

From Artwork to Print-Ready File in 4 Steps

We handle the entire separation process — you send the artwork, we deliver organized PSD files ready to burn to screens.

01

Send Your Artwork

Send any file — PNG, JPG, PSD, AI, PDF, TIFF, CDR. We analyze the design and determine the optimal ink palette and channel count.

02

Color Analysis

We hand-build the ink palette — typically 6–8 spot colors — and apply color correction, contrast adjustment, and PANTONE® matching.

03

Halftone Separation

Each channel is halftoned with custom LPI, dot shape, and screen angle. Underbase and highlight whites are created and choked properly.

04

File Delivery

You receive a clean, organized PSD with named layers, print-order notes, and ink recommendations. Ready for RIP or direct film output.

What's Included

Everything You Need to Print

Every simulated process separation is hand-crafted by an experienced color separator — not automated software. We analyze your artwork, build the color palette manually, and calibrate every halftone for your specific press and mesh count.

We ask about your press type, mesh count, ink brand, and substrate so we can optimize the halftone frequency and dot gain compensation for your exact setup — manual or automatic press, any ink system.

Up to 8 spot color channels
White underbase (dark shirts)
Highlight white channel
Color correction & adjustment
Brightness & contrast tuning
PANTONE® color matching
Custom LPI & halftone angles
Trapping between channels
Print order recommendation
Revisions included
Named PSD layers
PostScript & RIP compatible
PSD LAYER STRUCTURE artwork_simulated_process.psd LAYERS BLACK 45° BLUE 75° RED 15° ORANGE 45° HIGHLIGHT 0° WHITE FLASH 0° WHITE UNDERBASE 0° 7 LAYERS · 300 DPI · GRAYSCALE CHANNELS · 45 LPI READY ✓

Delivered as a layered PSD — each channel halftoned and labeled

Why Simulated Process

The Right Choice for Complex, Photo-Realistic Artwork

When your design has photos, skin tones, gradients, or more than 6 flat colors — simulated process is the only screen printing method that can do it justice.

Photo-Realistic Quality

Reproduce portraits, photographs, and detailed illustrations on dark garments with stunning accuracy. Simulated process is the only screen printing technique capable of matching photographic quality on apparel.

Dark Garment Friendly

Works beautifully on black, navy, dark gray, and any colored shirt. Our white underbase and halftone calibration ensure vibrant, accurate color reproduction on the darkest fabrics.

Print-Ready PSD Files

Every separation delivered as an organized Photoshop file — one layer per ink channel, correct screen angles, halftones applied, and ready for film or CTP output. Compatible with any RIP software.

How It Compares

Simulated Process vs Other Separation Methods

Choosing the right separation method depends on your garment color, design complexity, and budget. Here's how they stack up.

Feature Simulated Process CMYK Process Spot Color
Works on dark garments ✓ ✗ ✓
Photo-realistic results ✓ Excellent ✓ On white only ✗ Flat colors only
Number of ink channels 6–10 4 1–8
White underbase needed Yes — included No Optional
Best for gradients ✓ Excellent ✓ On white ✗
Price range $25–$60 $20–$40 $15–$35
Typical use case Band merch, art prints, dark apparel Photos on white shirts Logos, brand marks
Common Questions

Simulated Process FAQ

Simulated process color separation uses 6–10 opaque spot-colored inks printed as halftone dots to optically reproduce photo-realistic images on dark garments. Unlike CMYK process printing, it does not rely on a white substrate — the opaque inks build color directly on dark fabric using a white underbase as the foundation. This makes it the preferred method for printing photographs and complex artwork on black shirts, hoodies, and colored garments.
CMYK uses four transparent inks (cyan, magenta, yellow, black) and relies on the white of the substrate to reflect light back through the inks. This only works well on white or very light-colored garments. Simulated process uses 6–10 opaque spot colors — including a white underbase — that can print on any dark fabric, achieving photo-realistic results impossible with CMYK on dark shirts.
Most simulated process jobs use 6–8 colors. A typical palette includes: white underbase, highlight white or yellow, orange, red, blue, and black. More complex designs with detailed skin tones or many gradient areas may need up to 10–12 channels. We optimize the ink count to balance cost and print quality — always aiming for the fewest colors possible while preserving the visual fidelity of your artwork.
We accept virtually every common format: PSD, AI, PDF, PNG, JPG, TIFF, EPS, CDR, and even PowerPoint or Publisher files. For best results, submit high-resolution files at 300 DPI or higher at the final print size. If your artwork is low resolution, contact us first and we will advise on whether it can be enhanced or vectorized for a clean separation.
Yes. We calibrate LPI and halftone dot shape specifically for manual press printing. Manual presses typically work best at 35–45 LPI with slightly larger dot shapes to ensure ink holdout on mesh counts of 110–160. We will ask about your press type and mesh count when you submit your artwork to optimize the separation for your equipment.
The most professional method is through a PostScript printer or RIP software (Raster Image Processor), which precisely converts the halftone channels to the output device. However, if you do not have RIP software, it is also possible to print separations directly from Photoshop on a standard (non-PostScript) printer. We include printing notes with every separation, and we are happy to walk you through the process — just ask when you order.
Standard turnaround is 24–48 hours. Same-day service is available for an additional fee — most same-day orders are delivered within 6–8 hours of artwork submission. Rush turnaround is also available for urgent deadlines. We will give you an accurate time estimate when you submit your artwork.

Ready for Photo-Realistic Prints?

Send your artwork today and get professional simulated process color separations. Same-day turnaround available — trusted by screen printers in the USA, Canada, and worldwide.

Send Your Artwork >Ask a Question

Accepts PSD · AI · PDF · PNG · JPG · TIFF · Same-day delivery available · From $25

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Leo Ortiz
● Online · Color Separation Expert

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