Sunnhemp is a coarse, strong and stiff bast fiber similar to jute fiber but not considered by textile technologists for the purpose of spinning into yarn, which can be further woven into fabric. The objective of this study was to spin 100% Sunnhemp fibers in to different yarns of same count on a jute spinning system by using different number of passages of carding and drawing to find how the structural changes in the fiber after each stage mechanical processing. To observe structural changes in the fiber, random sampling method was used to collect the fiber samples at various stages of processing and analysis of each fiber was done using microscope. It was found that a lot of changes occur in the fiber structure due to mechanical processing. The structural details about the fiber entity are depicted in the article. Further, correlation was established between various fiber parameters such as fiber length, fiber diameter and fiber number of branches. Finally, an exponential frequency distribution of the fiber lengths for various stages in the spinning process was calculated. This curve explains how the degree of individualization increases as the fiber length decreases and makes the fiber spinnable into better quality yarn.