The behaviour of fluid flow in industrial processes is essential for numerous applications and there have been vast amount of work on the hydrodynamic pressure generated due to the flow of viscous fluid. One major manifestation of hydrodynamic pressure application is the wire coating/drawing process, where the wire is pulled through a unit either conical or cylindrical bore filled with a polymer melt that gives rise to the hydrodynamic pressure inside the unit. The hydrodynamic pressure distribution may change during the process due to various factors such as the pulling speed, process temperature, fluid viscosity, and geometrical shape of the unit (die). This work presents the process of designing a new plasto-hydrodynamic pressure die based on a tapered-stepped-parallel bore shape; the device consists of a fixed hollow outer cylinder and an inner rotating shaft, where the hollow cylinder represents a pressure chamber and the rotating shaft represents the moving surface of the wire. The geometrical shape of the bore is provided by different shaped inserts to set various gap ratios, ancl the complex geometry of the gap between the shaft and the pressure chamber is filled with viscous fluid materials. The device allows the possibility of determining changes in the hydrodynamic pressure as the shaft speed is altered while different fluid viscosity during the process is considered. A number of experimental procedures and methods have been carried out to determine the effects of various shaft speeds by using Glycerine at 1 to 18 °C and two different types of silicone oil fluids at 1 to 25 °C on the hydrodynamic pressure and shear rate. Viscosities of the viscous fluids were obtained at atmospheric pressure by using a Cone-plate Brookfield viscometer at low shear rate ranges. Moreover, Computational fluid dynamics (CFD) was used to develop and analyze computational simulation models that demonstrate the pressure units, which studies the drawing process involving viscous fluids in a rotating system. A finite volume technique was used to observe the change in fluid viscosity during the process based on non-Newtonian characteristics at high shear rate ranges. The maximum shaft speed used in these models was 1.5m.sec'1. Results from experimental and Computational models were presented graphically and discussed.