Simulated Process Separation
The most widely used separation technique for screen printing complex artwork. Simulated process uses AM halftone dots to mimic the appearance of full photographic colour using a limited ink set.
Get a QuoteMost common request
Simulated process is the most frequently requested separation type we handle. It's the go-to method for garment printers working with complex, multi-colour artwork.
Typical ink count
A simulated process job typically uses 6–10 screens: highlight white, shadow, 3–5 colour channels, and an underbase. We optimise the channel count to balance quality against press practicality.
What Is Simulated Process?
Rather than printing one ink per colour (spot colour), simulated process uses halftone dot patterns in multiple channels that blend on-press to create the illusion of thousands of colours.
The separation software analyses the artwork and distributes each tonal area across several ink channels. When printed, the dots of different inks overlap and optically mix — producing gradients, shadows, and highlights with just 6–10 screens.
Correct halftone angles are critical. Misaligned angles cause moiré patterns — an unwanted interference effect. We set angles precisely based on the ink count and mesh specification.
Best For
- Photo-realistic and gradient-heavy artwork
- Multi-colour designs on black or dark garments
- Complex illustrations with many tonal transitions
- High-fidelity prints where colour depth matters
What We Deliver
- 6–8 separated channels (varies by artwork complexity)
- Underbase (white underprint) channel for dark garments
- Highlight white channel where required
- Correct halftone angles to prevent moiré
- Dot gain compensation for your mesh count
- Press-ready films or RIP-ready files