I created Simulated Process artwork to go on Dark & Light Apparel. Up to 9 colors to be printed using Pantone Colors. I use Illustrator & Photoshop.
Tools: 
Step 1. Start with a high resolution image in photoshop 
Step 2. Add distressed brushes for work look. 
Step 3. Open image Separation Studio 4. Merge colors I don't need to print. 
Step 4. Use curves to make image better, name colors that will use Pantone colors.
Save file for fill separation.  
I added a 2nd Pantone 289 c screen to go white apparel. Navy shirt is a 4 color.
White shirt is a 2 color. 
9 color simulated process on Black shirt.
Step 1. Get image ready in Photoshop. 
Step 2. Create effects. 
Step 3. Open image Separation Studio 4. Merge colors I don't need to print. 
Step 4. Use curves to make image better, save file for fill separation. 
9 Color Simulated Process on Black shirt. 
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