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Although many developments have been made in composite yarn research field during last few decades but there are certain areas which need attention of researchers.Most of researhes have been carried out in filament core staple sheath spinning area but very little research work is available in the area of filament wrap staple core spinning.This type of yarn structure can be helpful to utilize the short staple fibers as core to improve absorbancy and reduce the cost whereas filaments wrapping will improve the mechanical properties of resultant composite yarn.Separation and spreading of multifilaments are considered important factors which affects the properties of bi-component compsite yam.Various multifilament spreading methods have been discussed in previous papers but almost every method has certain negative aspects or limitations associated to it.This research work describes a new technique for producing filament wrap-staple core composite yam, with the help of an innovative multifilament spreading method, using slightly modified ring frame.The purpose is to develop an efficient and economic process for uniform multifilament spreading to improve wrapping of multi filament around staple core.Spreading apparatus which uses a microgrooved roller for monofilament separation was designed and mounted on conventional ring frame.Scanning electron microscopy was used to study the role of micro grooves size in monofilament web formation, to understand the possible correlation in context of uniform spreading and its effects on cover spun yarn properties.Polyester multi filament and cotton roving were spun into 12 Ne cotton core polyester wrap yam on modified ring frame using the spreading apparatus; similar yarn was also made on conventional spinning frame and both types were then tested to compare the key properties like tenacity, extension and hairiness etc. It was concluded this micro grooved roller spreading method can be used to overcome the problems associated with other spreading techniques reported earlier and help to improvecomposite yam properties.