Why Colour Separation Matters in Apparel Printing

Accurate Colour Reproduction

Proper separation ensures colours print exactly as intended, without unwanted blending or distortion.

Clean, Sharp Prints

Well-separated colours lead to crisp edges and professional-quality results.

Cost Control

Efficient colour separation helps minimise the number of screens used, reducing setup and production costs.

Common Colour Separation Methods

Spot Colour Separation

Used for simple designs with solid colours. Each colour is printed as its own layer.
Ideal for logos, text, and branding.

CMYK Colour Separation

Breaks artwork into Cyan, Magenta, Yellow, and Black for full-colour photographic prints.
Common in simulated process printing.

Simulated Process Separation

Uses spot colours instead of CMYK to recreate gradients and photo-realistic effects.
Best for dark garments and complex designs.

Index Colour Separation

Uses a limited colour palette with tiny dots to simulate shading and gradients.
Popular for cost-effective, detailed prints.

Colour Separation in Different Printing Methods

Screen Printing

Colour separation is critical—each separated colour requires a separate screen.

DTG Printing

No manual colour separation needed; the printer handles it digitally.

DTF Printing

Artwork is printed as a single film image, so colour separation is handled automatically by RIP software.

Sublimation Printing

Does not require traditional colour separation, as the design prints as a full-colour image.

Software Used for Colour Separation

Adobe Photoshop

Most widely used for simulated and index separations.

Adobe Illustrator

Best for vector-based spot colour separations.

CorelDRAW

Popular in apparel and sign printing industries.

RIP Software

Automates separations, ink limits, and halftone settings for production accuracy.

Key Factors That Affect Colour Separation Quality

Artwork Quality

High-resolution files produce cleaner separations.

Colour Choice

Overlapping or similar colours can cause muddy prints if not separated properly.

Garment Colour

Dark garments often require underbases and special separations.

Ink Type

Plastisol, water-based, and discharge inks each require different separation approaches.

Colour Separation vs CMYK Printing

Screen Count

Colour separation focuses on individual inks, while CMYK relies on four process colours.

Print Feel

Spot colour separations often produce bolder, more opaque results.

Durability

Spot colour screen prints are generally more durable than CMYK screen prints.

Common Colour Separation Issues

Colour Bleeding

Occurs when separations overlap incorrectly.

Registration Problems

Poor alignment between separated colours can cause blurred edges.

Excessive Screens

Over-separating colours increases cost without improving quality.

Best Practices for Colour Separation

Keep Designs Simple

Fewer colours mean fewer screens and lower costs.

Test Prints

Always sample complex separations before full production.

Work With Print-Friendly Colours

Avoid unnecessary gradients if screen printing.

Why Colour Separation Is Essential in Custom Apparel Printing

Colour separation is a foundational step in professional garment printing. When done correctly, it ensures accurate colour reproduction, clean prints, cost efficiency, and long-lasting results—especially in screen printing workflows used across the Australian apparel industry.