High-Quality Color Separations for Photorealistic Screen Printing
Simulated process printing can produce some of the most impressive work in screen printing.
Rich shadows. Bright highlights. Smooth tonal transitions. Detailed artwork on black and dark garments.
But the quality of the finished print starts long before ink reaches the shirt.
It starts with the separations.
At Kolormatrix, we offer professional simulated process color separations for screen printers who want production-ready files built for real-world printing.
Whether you are printing on a manual press or an automatic, our goal is simple:
Give you separations that are easier to print, easier to register, and built around the number of colors your press can actually handle.
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What Is Simulated Process Printing?
Simulated process is a screen-printing separation method that recreates detailed, full-color artwork using a limited number of spot-color inks.
Unlike standard CMYK process printing, simulated process does not rely only on cyan, magenta, yellow, and black.
Instead, the artwork is separated into the specific ink colors needed to reproduce the image effectively.
That may include:
- an underbase
- highlight white
- black
- red
- blue
- yellow
- green
- orange
- gray
- other spot colors as needed
The exact number of colors depends on the artwork and the limitations of your press.
The goal is not to use more screens than necessary.
The goal is to use the fewest practical colors needed to create the strongest finished print.
Why Simulated Process Works So Well on Dark Shirts
Dark garments create a challenge.
Without a white base, many ink colors lose brightness and opacity.
That is why simulated process separations often use a carefully controlled white underbase.
The underbase helps support the color layers while preserving detail and tonal transitions.
A highlight white may also be used to strengthen:
- bright whites
- reflections
- facial highlights
- metallic-looking details
- high-contrast areas
When the underbase, colors, and highlight white work together correctly, the result can be a highly detailed print with strong depth and contrast.
Flat-Rate Pricing
Standard Simulated Process Separation — $75
We charge a flat $75 for standard simulated process separations.
We do not charge by the number of colors used in the separation.
Why?
Because a good separation should be built around what the image actually needs and what your press can handle.
A 6-color job is not automatically easier than an 8-color job.
A 9-color separation may be exactly what is needed for one image, while another may print beautifully with fewer screens.
Our job is to build the separation around the artwork and your production setup.
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Turnaround Options
Choose the turnaround that fits your production schedule.
Standard — 72 Hours
Best for planned production and normal scheduling.
24-Hour Rush
For jobs that need to move quickly.
Same-Day Rush
For urgent production when time matters most.
Availability may depend on workload and file quality.
What We Need From You
Better information helps us create better separations.
When you place your order, please include:
- garment color or colors being printed
- maximum number of colors your press can print
- any specific ink or production requirements
- any special concerns about the artwork
- any important print-size or placement details
If additional information is needed, you can email:
art@kolormatrix.com
Please include your order number with any follow-up details.
Artwork Requirements
Your artwork should be supplied at:
Final Output Size
Do not send a small image and expect it to be enlarged dramatically without losing quality.
The file should already be close to the size you intend to print.
300 PPI or Higher
For best results, provide artwork at 300 PPI or higher at final output size.
Higher-quality source artwork gives us more detail to work with during separation.
Transparent PNG Preferred
A transparent-background PNG is preferred when available.
This helps eliminate unnecessary cleanup and gives us a cleaner starting point.
Accepted File Types
We currently accept:
- PNG
- PSD
- EPS
If you are unsure whether your file is suitable, contact us before ordering.
Why File Quality Matters
Simulated process relies on tonal information.
If the original file is:
- low resolution
- heavily compressed
- pixelated
- blurry
- badly enlarged
the separation cannot restore detail that is not present in the source image.
That is why proper artwork preparation matters.
The better the source artwork, the better the separation can be.
Built Around Your Press
One of the most important things we need to know is:
How many colors can your press actually print?
There is no benefit in creating a 10-color separation for a shop that can only run 6 colors.
When we know your press limitations, we can make better decisions about:
- which colors are most important
- where colors can be combined
- how much information can be carried by the underbase
- where highlight white should be used
- how to simplify the separation without destroying the image
That makes the separation more practical for production.
Garment Color Matters
The same artwork may need to be separated differently for:
- black shirts
- navy shirts
- red shirts
- royal blue shirts
- white shirts
- light-colored garments
The garment itself becomes part of the final print.
That is why we ask you to tell us what colors you will be printing on.
A separation built specifically for a black shirt may not perform the same way on a red or navy garment.
Underbase and Highlight White
A strong simulated process separation is not just a stack of color channels.
The white layers matter.
Underbase White
The underbase creates the foundation for color on dark garments.
Too much underbase can make the print feel heavy and reduce tonal depth.
Too little can make the colors appear weak or muddy.
Highlight White
Highlight white can restore brightness and sharpness in selected areas.
Used correctly, it can help add:
- depth
- contrast
- clean whites
- sparkle
- reflected light
- finishing detail
The goal is balance.
Choke and Registration
Registration is critical in simulated process printing.
If the underbase extends too far beyond the color layers, you may see unwanted white edges.
That is why choke settings matter.
A properly prepared separation helps reduce registration issues by controlling how the white base sits beneath the color channels.
Good separations should support real production, not just look good on a computer screen.
Print Order Matters
The order in which the colors are printed can affect the final result.
A professional simulated process separation should consider:
- underbase placement
- darker versus lighter colors
- opacity
- wet-on-wet interaction
- highlight white
- final contrast
The exact print order may vary depending on the artwork and ink system.
That is why separation is both technical and visual.
Simulated Process vs CMYK Process
These are not the same thing.
CMYK Process Printing
Uses:
- Cyan
- Magenta
- Yellow
- Black
and is commonly used on white or light garments.
Simulated Process Printing
Uses a custom set of spot colors chosen specifically for the artwork.
It is especially effective for:
- black garments
- dark garments
- highly detailed illustrations
- photographic artwork
- high-contrast images
- artwork requiring strong opacity
Simulated process gives the separator more control over how the image is reproduced.
Who Is This Service For?
Our simulated process separation service is ideal for:
- professional screen printers
- manual press operators
- automatic shops
- contract printers
- apparel decorators
- schools and training programs
- printers adding advanced color work
- shops printing detailed artwork on dark garments
You do not have to buy ink or equipment from Kolormatrix to use the service.
This is a standalone artwork service.
What This Service Does Not Include
The $75 simulated process separation service is for artwork that is already suitable for professional separation.
It does not automatically include:
- major redraws
- logo reconstruction
- extensive retouching
- compositing multiple images
- redesigning the artwork
- rebuilding badly damaged files
If the source artwork requires major repair before it can be separated, additional artwork services may be necessary.
Why Use a Professional Separator?
Simulated process is one of the easiest techniques to make look bad when the separations are weak.
Poor separations can cause:
- muddy color
- weak opacity
- too much white
- difficult registration
- too many unnecessary screens
- poor tonal range
- flat-looking prints
- wasted setup time
A good separation is designed with the press operator in mind.
The goal is not to create the most complicated separation.
The goal is to create one that prints well.
Ideal Artwork for Simulated Process
Simulated process works especially well for:
- portraits
- wildlife
- fantasy artwork
- automotive art
- sports graphics
- patriotic artwork
- detailed illustrations
- high-contrast imagery
- complex photographic designs
If the image has tonal depth, shadows, highlights, and multiple colors, simulated process may be a strong option.
What You Receive
Your final separation package is prepared for production based on the information you provide.
The exact output may vary by artwork, but the goal is to provide:
- production-ready separated color channels
- underbase as needed
- highlight white as needed
- practical color count
- separation built around your press limitations
Need Help Before Ordering?
If you are not sure whether your artwork is a good candidate for simulated process, contact us before placing the order.
We can help determine whether:
- simulated process is the right approach
- your file quality is sufficient
- your press has enough colors
- additional artwork work may be needed
Email:
art@kolormatrix.com
Order Simulated Process Separations
Ready to get started?
Choose your turnaround time, upload your artwork, tell us your garment color and press-color limit, and submit your order.
Standard — 72 Hours
24-Hour Rush
Same-Day Rush
[ORDER SIMULATED PROCESS SEPARATIONS]
Related Screen Printing Resources
- Professional Screen Printing Training
- 3-Day Professional Screen Printing Class
- Screen Printing Resources
- Artwork & Separations
- White Plastisol Ink Guide
- Mesh Count Guide
- Screen Making Resources