Simulated Process Color Separations for Screen Printing

Simulated Process Color is the best choice for screen printing photo-realistic images containing thousands or millions colors.

Standard Colors

Yellow Ink
Red Ink
Blue Ink
Light Blue Ink
Green Ink
Black Ink
Light Blue

You can be used Simulated Process for printing the majority of images because this method is ideally intended for full-color printing.

1.Color Separation Services

Printing quality and low cost will depend on quality of your artwork and professional color separation.
We always aspire to make high-quality color separations with the fewest possible colors. It will allow your company to reduce printing costs.

Our Services Include:
Light T-Shirts
Dark T-Shirts
Color separation of your artwork into 8 or less spot colors.
Up to 12 Spot Colors*
Up to 12 Spot Colors*
White Base for dark T-Shirts
White Base for light colored or pastel T-Shirts
Highlight White
Color Correction **
Brightness and Contrast Adjustment **
White Balance Adjustment **
General Guidelines and Instructions:
How to Print Color Separations from Photoshop?
Creating Halftone Dots without a RIP!
(You can use a Postscript or not-PostScript printer.)
How to Print Color Separations in Adobe Illustrator?
(Creating Halftone Dots in Illustrator)
How to Print Color Separations in CorelDRAW? (Creating Halftone Dots in CorelDRAW)
How to create a curve, to compensate for Dot Gain?
How to set up color profiles?
Fast Turnaround:
Max. 24 hours
Max. 24 hours
Total Price:
$ 35.00 USD per file
$ 35.00 USD per file

* - PMS Colors (PANTONE® Matching System)
** - Minimum Adjustment

2. Custom Color Separation

If you need special colors, please choose colors from the PANTONE® Matching System (PMS) and indicate numbers on your order.

3. Printing Color Separations

To print Simulated Process (Spot Color Separations) from Photoshop, you should use a PostScript printer or a RIP software (Raster Image Processor).

The PostScript is language that describes your page and sends instructions to a PostScript printer. It is the standard for high-quality printing.

If you do not have PostScript printer or a RIP software, there is a simple way that will allow you to print separations from Photoshop on a non-PostScript printer. After color separation of your file, we will send you a link to download a file from our web server and all needed instructions.

What is a halftone?

The halftone is an image that is composed of solid dots of different size and are used to reproduce a continuous tone.

Halftone (22.5 Degrees, Elliptical Dot Shape, 45 LPI)
Halftone (22.5 Degrees, Elliptical Dot Shape, 45 LPI)
Halftone Dots for Screen Printing (Elliptical Dots)
70% Dots 50% Dots 30% Dots 10% Dots
70% Dots 50% Dots 30% Dots 10% Dots

Simulated Process Color

Original Image 6 Spot Colors White Base Yellow
Original Image Simulated Process Color (6 Spot Colors) White Base for Black T-Shirts Yellow  Screen
Red Green Highlight White Black
Red Green  Screen Highlight White Black  Screen

4. Acceptable File Formats

We accept the following PC or MAC file formats:

Preferred file format:


Other file formats:

  • ADOBE Illustrator (*.EPS, *.AI)
  • ADOBE Acrobat (*.PDF - Portable Document Format)
  • MACROMEDIA FREEHAND (*.EPS, *.FH5, *.FH7, *.FH8, *.FH9, *.FH10)
  • CORELDRAW (*.PSD, *.EPS, *.TIF, *.AI, *.CDR)
  • COREL Pointer (*.PSD, *.EPS, *TIF)
  • COREL Photo Paint (*.PSD, *.EPS, *TIF)
  • COREL Paint Shop Pro (*.PSP)
  • JASC Paint Shop Pro (*.PSP) (JASC Software Inc.)
  • QUARKXPRESS (*.EPS) (Choose File --> Save Page as EPS)
  • KODAK Photo CD (*.PCD)
  • MICROSOFT PowerPoint (*.PPT)
  • MICROSOFT Publisher (*.PUB)
  • TIFF (*.TIF; *.TIFF - Tagged Image File Format)
  • JPEG (*.JPG, *.JPEG - Joint Photographic Experts Group Bitmaps)
  • JPEG2000
  • BMP (*.BMP - Windows Bitmap)

5. How to place an order?

For more information, see Overview.

6. General Guidelines

Printed Sequence

  1. White Base for Dark T-Shirts
  2. Yellow
  3. Red
  4. Blue
  5. Light Blue
  6. Green
  7. Highlight White
  8. Black


  • 100% Cotton, Cotton Blends

Screen Printing Meshes

  • For screens use high-quality polyamide meshes such as SAATI, SEFAR or DYNAMESH.

    (Monofilament Polyamide Meshes)

Mesh Count

  • Manual Printing

    PANTONE® Colors (Spot Colors)
    230-305 threads/inch (90-120 threads/cm) - (Good results)
    305-330 threads/inch (120-130 threads/cm) - (Fine detail)

    "White Base"
    180-230 threads/inch (70cm-90 threads/cm)

    "White Highlight"
    180-230 threads/inch (70cm-90 threads/cm)

  • Automatic Printing

    PANTONE® Colors (Spot Colors)
    330-355 threads/inch (130-140 threads/cm) - (Fine detail)

    "White Base"
    180-230 threads/inch (70cm-90 threads/cm)

    "White Highlight"
    180-230 threads/inch (70cm-90 threads/cm)

Mesh Color

  • We recommend dyed mesh, for holding small dots.


Screen Angles

  • Use for all screens an angle of 22,5 degrees.

Screen Tension ( N/cm )

  • Screens should have an identical tension 25 - 30 Newton's.

Screen Printing Inks

  • For the best results use PLASTISOL inks.

Screen Printing Emulsions

  • For plastisol inks use diazo-photopolymer emulsions, also known as dual-cure emulsions.

Squeegee Type

  • Triple (70/90/70)

Screen Frequency

  • Manual Printing

    45 lpi (lines per inch) - (Good results)

    55 lpi (lines per inch) - (Fine detail)

  • Automatic Printing

    65 lpi (lines per inch) - (Fine detail)

Dot Shape

  • Use the Elliptical dot shape.

7. The Best Books for Photoshop and Screen Printing

8. The Best Graphics Software

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Simulated Process Color Separations