Polymerization of feed material takes place in reactor vessels with pure water. The resulting polymer is purified, dried and stored in preparation for dissolving in a concentrated solution of nitric acid. The "dope" liquid formed is then cooled, filtered, and de-aerated in preparation for spinning
The dissolved Polymer is extruded through Spinnerettes in a strong solution of nitric acid. Spinnerettes are a stainless steel unit with many thousands of small holes. As the Polymer emerges from the holes it coagulates to form fiber filaments. The solution of nitric acid mixes with a water solution which is pumped continuously around the spinning baths in which the spinning process takes place. Once the filaments are formed they are carried on to be washed clean of the remaining nitric acid.
The fiber is then stretched to improve its strength and to transform it to a more "wool" like product. Two separate drying and oiling processes are carried out to improve the anti-static properties and the process ability of the fiber. The fiber is then set by steam heating to an exact temperature for a controlled time period. This standardizes the dimensional stability and the dyeability of the fiber so that color is guaranteed during downstream dying.
The tow, which is a "rope" like fiber, is packed into bales. Stable fiber is soft crimped and then cut to selected lengths before baling.