Abstract: The invention comprises a continuous, integrated process to produce a multiple layered energetic material where the layers comprise energetic materials having, at least, two different burning rates. The process uses at least two twin-screw extruders to process at least two different energetic materials. These energetic materials are extruded into a co-extrusion die that, first, thins each energetic material flow into layers, and, then, combines the layers into a multiple layered energetic material. One embodiment of the invention also includes a remote take away system that completes processing the multiple layered energetic material after it leaves the co-extrusion die. The outer edges of the multiple layered material are first trim cut, then rolled into wrapped spools. Finally, the wrapped spools are cut into specified lengths for final use. These cutting, trimming and rolling steps are all done automatically, with no personnel handling required.