Color Separations
Engineering Accuracy from the Start
In high-fidelity screen printing, the margin for error is non-existent; the success of a project is determined long before the ink hits the substrate. Utilizing mathematically precise Color Separations is not merely a premium service—it is a foundational requirement. By engineering the file with absolute accuracy during the prepress phase, we eliminate the volatile “guesswork” that typically results in misaligned registrations, wasted films, and expensive production delays.
Starting with a technically sound separation ensures that every screen is optimized for the press, allowing for a seamless transition from digital concept to physical reality. This disciplined approach preserves the integrity of the design, ensuring that even the most complex “continuous tone” graphics are rendered with surgical precision and consistent vibrance across the entire production run.
The 5 kinds of Color Separations
Vector and Raster graphics
1. Vector
Spot Color Separation | Vector
In this process, colors are isolated from one another (knocked out). A graphic may contain the same color in various locations throughout the image, but each remains technically isolated. Even when a design features gradients that blend between tones, the colors are still meticulously separated from each other. It is important to note that Spot Color Separation refers to this technical preparation process and is not a specific type of ink.
Output Settings
LPI Solid: 45 for simple Spot Colors
LPI Gradients : 55 for simple Spot Colors with Gradients
Dot: Elliptical
Angle: 45°
Screen Mesh
Base: 110 – 160
Solids: 110 – 160
Basic Gradients: 160 – 300
Color Separation Pricing
Solid Spot Colors: $30.00 – $60.00
Basic Gradients Spot Colors: $40.00 – $100.00
Complex Gradients Spot Colors: $60.00 – $150.00
2. Raster
Spot Color Separation | Raster
In raster-based graphics, colors are isolated from one another through a technical “knockout” process. While a single design may feature the same color in multiple areas, each instance remains technically separated. This method allows for the management of both basic and advanced gradients; even as tones blend across large sections of the image, the underlying color data remains distinct. It is essential to understand that Spot Color Separation is a specialized prepress process and does not refer to a specific type of ink.
Output Settings
LPI Solid: 45 for simple Spot Colors
LPI Gradients : 55 for simple Spot Colors with Gradients
Dot: Elliptical
Angle: 45°
Screen Mesh
Base: 110 – 160
Solids: 110 – 160
Basic Gradients: 160 – 300
Color Separation Pricing
Solid Spot Colors: $50.00 – $80.00
Basic Gradients Spot Colors: $80.00 – $150.00
Complex Gradients Spot Colors: $150.00 – $400.00
3. Index
Spot Color Separation | Index
Indexed Color is a sophisticated technique used to manage a digital image’s color palette by limiting it to a specific, predefined set. Functioning as a form of vector quantization compression, this method isolates colors from one another through technical “knockouts.” Even when a graphic utilizes the same color in multiple locations or features complex gradients blending across large areas, each color remains independent and separated. This precise mapping ensures that intricate transitions are preserved while maintaining the structural clarity required for production. It is important to remember that Spot Color Separation is a technical prepress process and is not a specific category of ink.
Output Settings
LPI Solid: 45 for simple Spot Colors
LPI Gradients : 55 for simple Spot Colors with Gradients
Dot: Elliptical
Angle: 45°
Screen Mesh
Base: 110 – 160
Solids: 110 – 160
Basic Gradients: 160 – 300
Color Separation Pricing
Solid Spot Colors: $50.00 – $80.00
Basic Gradients Spot Colors: $80.00 – $150.00
Complex Gradients Spot Colors: $150.00 – $400.00
4. Process (CMYK)
Process Color Separation | Process CMYK
The 4-Color Process operates using four specific channels: Cyan, Magenta, Yellow, and Black (CMYK). In this method, these four colors are combined during the printing process through varying halftone dot sizes to achieve a spectrum of thousands of colors. While this technique is a standard in offset printing, it requires rigorous color profilingto ensure accuracy between the digital file and the physical output.
Because CMYK inks are transparent by nature, they rely on the reflective quality of the substrate; therefore, they are strictly intended for use on white backgrounds. This process allows for the reproduction of complex, photographic imagery by strategically layering these primary tones to create a full-color visual result.
Output Settings
1. Yellow – 75° screen angle
2. Magenta – 45° screen angle
3. Cyan – 15° screen angle
4. Black – 75° screen angle
5. Highlight white – 15° screen angle
6. Spot colors – 15° screen angle
Screen Mesh
Base: 300
Solids: 300
Basic Gradients: 300
Color Separation Pricing
No color separation fee.
Color profiling if necessary: $150.00 – $400.00
5. Simulation Process (CMYK Simulation)
Simulated Process Color Separation | Simulation
Simulated Process is a sophisticated technique primarily used to reproduce fine art or photorealistic imagery containing hundreds of colors. This method is exceptionally effective for graphics with high-detail complexity, such as single pixels of the same color situated far apart within a large design. It utilizes a combination of oil-based (plastisol) and water-based inks to achieve a high-fidelity finish that captures the nuances of the original artwork.
To maximize clarity and minimize interference with the square mesh of the screens, the most effective results are achieved by outputting separations with elliptical dots at a frequency of 55–65 LPI (Lines Per Inch). Setting all inks to a 45° angle ensures a smooth, continuous-tone appearance, allowing for the precise rendering of intricate gradients and photographic textures on the final substrate.
Output Settings
LPI Solid: 45 for simple Spot Colors
LPI Gradients : 55 for simple Spot Colors with Gradients
Dot: Elliptical
Angle: 45°
Screen Mesh
Base: 110 – 300
Solids: 110 – 300
Basic Gradients: 200b – 300
Color Separation Pricing
Basic Separation: $70.00 – $150.00
Advanced Separation: $200.00 – $1000.00
Color Correction: $100.00 – $500.00