It is disclosed a method of producing a yarn having the look and feel of natural fibers, the method comprising the steps of preparing a first plurality of man-made textile fibers or a second plurality of natural textile fibers, the first and second plurality of textile fibers being obtained from breaking the first or the second textile fibers under the effect of a mechanical force applied to the first or the second textile fibers. A final blend for producing the yarn, can be prepared by adding the first plurality of textile fibers to a plurality of man-made fibers, or by adding the second plurality of textile fibers to a plurality of man-made fibers, or by adding the first plurality of textile fibers to the second plurality of textile fibers.

Systems for producing M bundles of filaments, wherein M?1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a thermoplastic polymer having a color, hue, and/or dyability characteristic, which are different from each other. Each spin station produces N bundles of filaments that form a yarn. Each spin station comprises N spinnerets through which filaments are spun from molten polymers streams received by the respective spin station and N spin pumps upstream of the N spinnerets for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in the yarn from each spin station.

Systems for producing M bundles of filaments, wherein M?1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a thermoplastic polymer having a color, hue, and/or dyability characteristic, which are different from each other. Each spin station produces N bundles of filaments that form a yarn. Each spin station comprises N spinnerets through which filaments are spun from molten polymers streams received by the respective spin station and N spin pumps upstream of the N spinnerets for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in the yarn from each spin station.

A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) grinding recycled PET bottles into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

Provided is a method for manufacturing a combined yarn bundle including the steps of bringing the two or more carbon fiber precursor yarns which travel approximately parallel to one another into contact with a first roller at a wrap angle of 20 or more. Then, the two or more carbon fiber precursor yarns are split into two and brought into contact with a pair of second rollers, so that the carbon fiber precursor yarns are rotated approximately 90 between the first roller and the pair of second rollers. Next, the carbon fiber precursor yarns delivered from one second roller are brought into contact with a third front roller and a third rear roller, and the carbon fiber precursor yarns delivered from the other second roller are brought into contact with the third rear roller without bringing them into contact with the third front roller, so that these carbon fiber precursor yarns are combined on the third rear roller. Thereafter, the carbon fiber precursor yarns delivered from the third rear roller are brought into contact with a fourth roller to obtain a combined yarn bundle. A ratio of a distance L between axes of the first roller and of the pair of second rollers to a yarn width W of the carbon fiber precursor yarn on the first roller, L/W, is 18 or more and a tension of the combined yarn bundle after delivered from the fourth roller is 0.11 cN/dtex or more.

Systems for producing M bundles of filaments, wherein M?1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a thermoplastic polymer having a color, hue, and/or dyability characteristic, which are different from each other. Each spin station produces N bundles of filaments that form a yarn. Each spin station comprises N spinnerets through which filaments are spun from molten polymers streams received by the respective spin station and N spin pumps upstream of the N spinnerets for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in the yarn from each spin station.

Systems for producing M bundles of filaments, wherein M?1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a thermoplastic polymer having a color, hue, and/or dyability characteristic, which are different from each other. Each spin station produces N bundles of filaments that form a yarn. Each spin station comprises N spinnerets through which filaments are spun from molten polymers streams received by the respective spin station and N spin pumps upstream of the N spinnerets for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in the yarn from each spin station.

A tufted geotextile for covering and closing land surfaces with shear resistance to hydraulic and dry-flow displacement of infill, having a backing sheet tufted with first yarns to form a plurality of first tufts that extend a first length as simulated grass blades and tufted with second yarns different from the first yarn for a plurality of second tufts extend a second length as simulated understory grass blades, said second tufts having distal ends that splay to form nexts of discrete fibers extending into interstices between the first and second tufts, and an infill received within the interstices, which next restrict hydraulic and dry-flow displacement of the infill. A method of tufting a geotextile for understory tufts and nests is disclosed. A method of covering outdoor land sites for increased resistance to high shear hydraulic and dry-flow events is disclosed.