Methods of forming composite rovings formed of reinforcing fibers coated with at least one matrix resin are provided. The matrix resin may be any thermoplastic or thermoset powder or thermoplastic or thermoset emulsion, and is applied to reinforcement fibers after a size composition has been applied. The matrix resin may be applied to the reinforcing fiber in an amount from about 20 to about 35% by weight of the composite fiber. The fibers travel a distance sufficient to dry the size and the matrix resin. In exemplary embodiments, the distance may be from about 20 to about 150 feet. A heating apparatus may be utilized to assist in drying the fibers. The end composite fiber product is a composite roving that is formed in one step during the glass forming process and can be used in further processing steps to form composite parts without the need to add additional resin.
