Most orders don’t require us to make simulated process separations, but if you need a photographic image screen printed onto non-white items, we may need them. Even some seemingly simple designs require simulated process separations if the blending from one ink to another needs to be precise. The most common art that needs these kinds of separations are photos of people’s faces. The colors need to gradually fade from one to another in the highlight and shadow areas in a very precise way. If they don’t fade just right, it looks terrrrrrrible.   These kinds of separations are unique to screen printing, very difficult, and are extremely time-consuming since there’s no software that does it well. Even with world-class separations, time is also needed on press to adjust and readjust how each ink prints, so these separations cost at least $35 per ink being printed, and there will usually be 6 to 8 screens, so usually $200-300(one-time charge).