This job only needed 5 colors. Base, gray, red, highlight, black. I did a sample separation and sent to the user.
There were a few issues on his end. It appeared the separation was being run on a file that was used previously to run a separation on as that additional color layer is present, which is generated and used by Simulated #3. Therefore, the file could be corrupt. Unlikely but possible.
In addition to that, the Photoshop Preferences file was most likely damaged, which is resulting in these solid channels. Additionally, the only image that should be open when running a separation is the image to be separated and nothing else.
Requested the user reset the Photoshop Preferences file.
http://www.ultraseps.com/reset-preferences.phpFollowed by opening the Illustrator file in Photoshop at 300 dpi and run Simulated #3.
Adjust the channels and you’re all set. Provided advice on how that should be done as well.
Directed user to this page on film output, as it contains everything you’ll ever need to know for all printing situations:
http://www.ultraseps.com/output-color-separations-to-film.phpNote: Many printers, especially those newer to Photoshop and separations think the term simulated process is correlated to higher-end, realistic separations only, when that's not the case. Simulated process is just a generic term that refers to breaking down an image that usually contains tonal transitions into a manageable number of spot channels within Photoshop. Its not a scary thing although it can take a little practice to become proficient.