A process for producing prills containing an energetic material other than ammonium dinitramide or ammonium nitrate, is performed in a prilling column having at least one heated zone and at least one cooling zone. A baking tool for use with a baking pan, the baking tool comprising a nylon portion comprising a lower, flat side; an upper, angled side opposite the lower, flat side; and a nylon tip wherein the upper, angled side meets the lower, flat side. Further, a pinning layer is disposed below the pinned layer. The second stage is auto-ignited combustion of the surrounding lean airfuel mixture induced by such additional cylinder pressure increase. A third formulation, comprising polymeric matrix material and reinforcements, is applied atop the barrier layer to create a reinforced layer.