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✨ Precision Color Separation for Flawless Screen Printing

We transform your digital artwork into print-ready files with expertly executed spot color, simulated process, and index color separation. Guaranteed accuracy for T-shirts and apparel printing.

Get Your Screen Printing Artwork Separated

The Foundation of High-Quality Screen Printing

Simulated Process Color Separation

Perfect for reproducing photorealistic images and complex graphics with gradients on dark-colored garments. This technique uses a limited number of spot colors (often 8-12) and halftone dots to trick the eye into seeing a full spectrum of color. It requires immense technical skill to create the base, highlight, and color channels accurately.

  • Photorealistic Results: Ideal for photographic or highly detailed artwork.
  • Dark Garment Solution: Includes a specialized white underbase for vibrant results on black and navy.
  • Cost-Effective: Uses fewer screens than true process printing while maintaining quality.
  • Halftone Precision: Expert creation of smooth gradients using LPI and angle adjustments.

We ensure your simulated process separation files include the critical choke and spread for perfect registration.

Spot Color & Vector Separation

For designs that use solid, non-blended colors—like corporate logos, bold text, or graphic illustrations—spot color separation is the solution. We convert every color in your artwork into a distinct Pantone-matched channel, ensuring exact color reproduction every time.

  • Pantone Matching: Guaranteed color accuracy for brand integrity.
  • Clean, Solid Prints: Eliminates gradients or dots, resulting in sharp edges.
  • Vector Ready: Ideal for vector-based artwork that needs minimal colors (typically 1-6).
  • Direct-to-Film Ready: Final files are formatted specifically for outputting film positives with registration marks.

Our vector color separation process minimizes screen setup time and ink costs for your printing operation.

Our Technical Color Separation Process

Art Analysis & Preparation

Before separation begins, we meticulously analyze your artwork's format and intended print medium (T-shirt, poster, etc.). We fix any inherent color mode issues (RGB to CMYK/Spot) and ensure the resolution is sufficient for large-scale printing. If needed, we perform Image to Vector conversion first.

  • Resolution Check: Ensuring 300dpi minimum for raster separation.
  • Color Auditing: Identifying and correcting non-printable colors.
  • Printing Intent: Separating based on the fabric color and desired print feel.

White Underbase & Highlight Generation

For printing on dark apparel, a white underbase is mandatory to achieve bright, opaque colors. We custom-create this base plate and the final highlight layer:

  1. The Underbase is custom-choked to be slightly smaller than the color plates, preventing white ink bleed.
  2. The Highlight Layer uses super-fine halftones to add the illusion of true brilliance and detail.

Print-Ready File Delivery

We deliver files that your screen printer can use instantly without further adjustments. Each file is provided as separate black-and-white channels, ready to be printed onto film positives.

  • Accurate Registration Marks: Essential guides for aligning each screen on the press.
  • Density Tested: Output channels are guaranteed 100% solid black for optimal film density.
  • File Compatibility: Delivered in PSD, AI, EPS, or high-res TIFF formats.

Frequently Asked Questions (FAQ) About Color Separation

What is Color Separation for Screen Printing?

Color separation is the process of breaking down a full-color graphic image into a series of single-color layers. Each layer corresponds to a specific ink color (often Pantone or process inks) that will be applied through a separate screen during the printing process. This is essential for creating the film positives needed to burn the screens.

What are the main types of color separation you offer?

We offer three primary types: Spot Color (for logos and simple graphics using defined ink colors), Simulated Process (for photorealistic images using a limited palette of spot colors, creating blends with halftones), and Index Color (using square dots for precise, high-detail reproductions).

Why is Simulated Process Separation often used for dark garments?

Simulated Process separation is ideal for dark garments because it allows complex, full-color designs to be printed with vibrant results. It typically includes a crucial white base layer and utilizes halftone dots and a limited set of bright spot colors to replicate the full spectrum of the original image.

What file formats do you deliver the final separations in?

We deliver production-ready files, usually in Adobe Illustrator (.AI), Adobe Photoshop (.PSD), or high-resolution PDF formats, all with registration marks and proper layer naming for immediate use by your screen printing team.

Ready for Print-Perfect Artwork?

Don't risk printing errors. Upload your design now and let our color separation experts handle the complexity.

Get Your Color Separation Quote