A combined geometry plasto-hydrodynamic pressure unit has been investigated theoretically and experimentally. Previous investigators have used either stepped parallel or tapered bore pressure unit for die-less drawing and/or coating of wires, tubes and stripes. In the present study a combined parallel and tapered bore unit has been used in conjunction with polymer melts as pressure fluid. In this present work a pressure unit is heated to convert the polymer feed into a viscous melt and the pressure in the fluid is generated by hydrodynamic action when a wire is drawn through it. Experimental work has been carried out on different pressure units with similar external but different internal geometries to investigate the performance of new pressure unit. Different types of polymer were used as the pressure medium. In this work analytical models based on Newtonian and pseudo-Newtonian characteristics have been developed to investigate the performance of the pressure unit and to optimise the process. The predicted results showed reasonable agreement those observed experimentally in magnitudes of maximum pressure. Experimental and theoretical results, showed that there exists a gap ratio (optimum) for which the pressure is maximum. For greater or smaller values of the gap ratio than the optimum value, a decreased magnitude for the maximum pressure was obtained. The maximum pressure at that gap ratio( optimum ) is much higher compared to those obtained using either stepped or tapered bore pressure unit at similar conditions.