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.

Methods of manufacturing bulked continuous carpet filament which, in various embodiments, comprise: (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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an MRS extruder (400) while maintaining the pressure within the MRS portion (420) of the MRS extruder (400) below about 25 millibars; (F) passing the resulting polymer melt through at least one filter (450) having a micron rating of less than about 50 microns; and (G) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an extrusion system while maintaining the pressure within the extrusion system below about 25 millibars; (F) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (G) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 25 millibars; (F) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (G) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

A process for the production of ethylene-based polymers from waste plastics feedstocks includes the steps in this order of: providing a hydrocarbon stream A obtained by treatment of a waste plastics feedstock; providing a hydrocarbon stream B; supplying a feed C including a fraction of the hydrocarbon stream A and a fraction of the hydrocarbon stream B to a thermal cracker furnace having cracking coil(s); performing a thermal cracking operation in the presence of steam to obtain a cracked hydrocarbon stream D; supplying the cracked hydrocarbon stream D to a separation unit to obtain a product stream E containing ethylene; supplying the product stream E to a polymerisation reactor; and performing a polymerisation reaction to obtain an ethylene-based polymer; wherein in step (d): the coil outlet temperature is ?800 and ?870? C.; and the weight ratio of steam to feed C is >0.3 and <0.8.

A nonwoven recyclable fabric and associated methods are provided. The fabric is formed from 100% polyester, and may also include surface coatings such as hydrophilic coatings to promote heat transfer as well moisture vapor transmission rates and/or a silicone coating to promote fabric smoothness and reduce abrasiveness of the fabric.

A method of manufacturing a film includes forming a blend containing a renewable content starch, a renewable content mineral, and polyethylene, operating a mass flow hopper to maintain a consistent mass flow rate of the blend to a feed throat of an extruder, and operating the extruder with a screw speed and melt temperature based on the amount by weight of the starch and mineral within the blend. The melt is passed through a screen pack with a mesh rating based on the amount by weight of the starch and mineral within the blend, is passed through a die, and is cooled into a film. The film is nipped to a gauge such that the film can be formed into a bag.

A method of manufacturing a film includes forming a blend containing a renewable content starch, a renewable content mineral, and polyethylene, operating a mass flow hopper to maintain a consistent mass flow rate of the blend to a feed throat of an extruder, and operating the extruder with a screw speed and melt temperature based on the amount by weight of the starch and mineral within the blend. The melt is passed through a screen pack with a mesh rating based on the amount by weight of the starch and mineral within the blend, is passed through a die, and is cooled into a film. The film is nipped to a gauge such that the film can be formed into a bag.

Provided is a method for manufacturing recycled plastic (B) from a plastic laminate (A) using an extrusion device having a melting and kneading unit in which a screw is disposed and an ejection unit. The method includes: supplying a plastic laminate (A) to the melting and kneading unit of the extrusion device; melting and kneading the plastic laminate (A) supplied to the melting and kneading unit with a screw rotation number 50 to 900 RPM to form a recycled resin composition (a); and ejecting the recycled resin composition (a) from the ejection unit and cooling the same to obtain recycled plastic (B). The plastic laminate (A) has at least a first resin layer, an adhesive layer and/or a printing layer, and a second resin layer. The content of a polyolefin resin is 80 mass % or more with a total mass of the plastic laminate (A) as a reference.

Provided is a method for manufacturing recycled plastic (B) from a plastic laminate (A) using an extrusion device having a melting and kneading unit in which a screw is disposed and an ejection unit. The method includes: supplying a plastic laminate (A) to the melting and kneading unit of the extrusion device; melting and kneading the plastic laminate (A) supplied to the melting and kneading unit with a screw rotation number 50 to 900 RPM to form a recycled resin composition (a); and ejecting the recycled resin composition (a) from the ejection unit and cooling the same to obtain recycled plastic (B). The plastic laminate (A) has at least a first resin layer, an adhesive layer and/or a printing layer, and a second resin layer. The content of a polyolefin resin is 80 mass % or more with a total mass of the plastic laminate (A) as a reference.