This study is designed to improve the processability of acrylic microfibres on the long-staple spinning system The introduction and uses of microfibres is traced, resulting in over-capacity and fierce price competition in the early 1990s with the need for further development and innovation apparent. Conducted in an industrial environment, the four yarn samples are specified and classified. Fabric properties were measured in accordance with recognized ISO and BS Standards. The results include reports on the incidence of fibre breakage in the stretch-breaker zone. Futher damage during the defelting process emerged. The effects of reduced throughput and speed are noted and combing problems detailed. Following preliminary trials evaluation, machine adjustments for microfibres were made and the results discussed. It is concluded that all production steps need great care and close monitoring with nep formation the most difficult problem requiring speed and throughput to reduced to ensure production continuity.