A method of manufacturing bulked continuous carpet filament from recycled polymer. In various embodiments, the method includes: (1) reducing recycled polymer material into polymer flakes; (2) cleansing the polymer flakes; (3) melting the flakes into a polymer melt; (4) removing water and contaminants from the polymer melt by dividing the polymer melt into a plurality of polymer streams and exposing those streams to pressures below 5 millibars; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

A system comprising: (1) a grinding unit configured to receive and grind recycled PET bottles into a group of polymer flakes comprising up to about ten percent colored polymer flakes and balance substantially clear polymer flakes; (2) a washing unit configured to wash the group of polymer flakes; and (3) an extruder configured to extrude material in a plurality of different extrusion streams. The extruder may be further configured to: (1) receive a concentrate-polymer mixture comprising a mixture of the polymer flakes and a color concentrate; (2) melt the concentrate-polymer mixture to produce a polymer melt; (3) reduce a pressure within the extruder; and (4) pass the polymer melt through the extruder so that the polymer melt is divided into the plurality of extrusion streams. The system may then filter the polymer melt through at least one filter and form the polymer melt into bulked continuous carpet filament.

Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) passing polymer flakes through a crystalliers; (2) melting the polymer to create a first single stream of polymer melt; (3) separating the first single stream of polymer melt into multiple streams of polymer melt; (4) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 25 millibars in a chamber; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

The invention relates to a method for decontaminating recycled plastic materials, which comprises the steps of selecting, grinding, washing, rinsing, drying and decontaminating, wherein decontaminating is carried out by means of the steps of extracting and rinsing, and extracting is carried out using a water-soluble solvent having a boiling point greater than 180 C. at atmospheric pressure.

A method for reducing an amount of a contaminant in a thermoplastic polymer comprising shearing a combination comprising a contaminated thermoplastic polymer in melt form, water, and a dispersing agent where the shearing causes a portion of the contaminant to be removed from the contaminated thermoplastic polymer (e.g. moved into an aqueous phase with the water or into another separate phase from the water and the polymer), and after shearing, separating the thermoplastic from the aqueous phase to recover thermoplastic polymer.

A method of manufacturing arch support socks according to one embodiment of the present invention may include an operation (a) of preparing a resin solution by mixing polyvinyl chloride (PVC) powder and dioctyl terephthalate (DOTP) liquid resin, an operation (b) of adding a heat stabilizer to the resin solution and stirring the resin solution, an operation (c) of removing impurities of the resin solution through sieving, a de-foaming operation (d) of removing bubbles in the resin solution in a vacuum state, an operation (e) of filling the de-foamed resin solution in a molding mold, an operation (f) of heating the molding mold, and an operation (g) of adhering an anti-slip part separated from the molding mold to an arch area of a sock bottom.