Color Separation Service

Method 01

Simulated Color Separation

Simulated color separation is the best choice when you want to print a multicolor design or a photorealistic picture on a dark garment — and standard CMYK process inks cannot achieve the result you need. This method uses 1-12 custom spot colors, each converted into a halftone raster at a specific ruling. The inks are semi-opaque, which gives better coverage on dark garments. Moreover, when overlapping in the wet-on-wet printing process, these inks create tonal transitions and additional mixed colors naturally.

Simulated process separation is the most popular method among screen printers because it tolerates slight press misregistration and still delivers acceptable results. Even a slightly imprecise setup on the machine gives you a good print.

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Method 02

Index Process Separation

Index process separation converts the design into a stochastic pattern of randomly placed, same-size rectangular dots — approximately ¼ of a standard halftone dot. Photoshop uses special algorithms to build colors from these scattered points, which allows photorealistic color reproduction and a soft hand feel on both light and dark garments.

Index separations typically use 6-13 colors. However, this method has a limitation: it does not handle long tonal transitions and highlights well. Therefore, I often combine index and simulated process separation into a hybrid approach — using halftone raster for gradients and index dots for the remaining colors.

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Method 03

Hybrid Separations

Hybrid separation combines the best of both methods. Colors with long tonal transitions use halftone raster for smooth gradients, while the remaining colors use index separation. As a result, you get the softness and detail of index printing together with the gradient capability of simulated process.

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Method 04

Real Process Color Separation (CMYK)

Real process separation uses 4 standard inks — Cyan, Magenta, Yellow, and Black — to reproduce a multicolor design. This method works best on white and light garments, where transparent inks can mix optically on the substrate.

This technique has several limitations. It does not reproduce bright colors like vivid green, orange, or skin tones accurately without adding extra spot color screens. Furthermore, each color channel uses a specific halftone ruling and angle — and if the angles are not precisely set, Moiré interference patterns appear between the screen lines and mesh fibers.

For best results with CMYK process, screens need high tension (25-35 N/cm²) and press registration must be precise. Therefore, this method works best on automatic presses where consistent pressure and registration are easier to control.

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Method 05

Spot Color Separation

Spot color separation is the standard method for designs where each color prints as a single specific ink — logos, text, bold graphics, and multicolored flat designs. Each color in the design becomes one screen. Spot colors are precise, repeatable, and do not require halftone or dithering.

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