High Color counts allow us to reproduce the finer details and colors in the photorealistic images. Above are some of the examples of what we printed recently.
Reproducing such art can be done in two ways.
Four Color Process
Four Color Process (also known ans CMYK or 4CP) works well on white and very light color garments, but in some cases can be done on dark backgrounds too. While the good quality Four Color Process printing is one of the hardest tasks in the garment printing industry, it pales in comparison with challenges involved in printing CMYK on darker shirts. We are proud to say that we have won awards for these difficult prints at more than one competition!
Simulated Process is similar to the 4CP, but it is designed to work well on darker garments. Unlike the translucent inks used in 4CP, regular high opacity plastisol covers the dark garments better and produces more vibrant images. It is also not restricted to four specific colors (CMYK) so some of the shades not available in 4CP (orange and brighter shades of green for example) can be reproduced by using Simulated Process.
Most of the printing seen today is actually done using the Simulated Process printing. It provides a wider color gamut and more vivid colors. Good visual of the color buildup is available at Netseps.com. As the separations are a highly complex process, they require years of training. We outsource all our separations to Dot-Tone-Designs in Orlando FL. The work is done manually and takes hours to complete (some of our award winners took 8-10 hours to separate!). Skilled labor at the world class level is expensive so the simpler designs start at $40 and can go as high as $500 for the highest grade, high color count separations.