Process for making spun-like yarn with variable denier filaments

A process for making a spun-like yarn comprising:

• (a) providing a feed yarn comprising a plurality of continuous polyester filaments, each of said filaments having been prepared by the steps comprising;
• (1) metering polyester polymer through a combined orifice to form molten polyester streams traveling in different extrusion speeds;
• (2) converging and attenuating said molten polymer streams to form a combined stream having thick and thin regions repetitively along its length;
• and
• (3) quenching said combined stream into a filament and withdrawing said plurality of filaments thereby forming said feed yarn;
• whereby each of said plurality of polyester filaments has a cross sectional area which varies repetitively from small values in thin regions to large values in thick regions along its length, said large values being at least 25% greater than said small values, said thick and thin regions being out of phase from filament to filament along length of said yarn;
• (b) drawing while heating and false twisting said polyester feed yarn, said drawing being at a draw ratio selected to break a plurality of said filaments primarily in said thin regions.