What is Simulated Process?
Technical definition, shop floor implications, and pricing strategies for commercial apparel decorators.
A color separation and printing technique that blends multiple opaque spot color inks using halftone dots to recreate complex, photographic illustrations on dark garments.
Deep Dive & Practical Application
While traditional 4-color CMYK process printing works only on white substrates using translucent inks, simulated process printing uses 6 to 10 opaque spot colors (such as white underbase, yellow, red, royal blue, green, grey, and highlight white) to produce photorealistic imagery on dark textiles.
Separation software uses Photoshop channel algorithms to break down the graphic into interlocking halftone screens. When printed wet-on-wet with specific flash stations on an automatic press, the opaque inks blend together optically on the fabric surface.
Shop Floor & Profitability Impact
Simulated process jobs command premium pricing ($8–$15+/garment) due to high screen counts (6–10 screens) and specialized darkroom calibration.
The Print Life Screen Printing Operating System
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