A method of manufacturing bulked continuous carpet filament, in various embodiments, comprises: (A) providing an expanded surface area extruder; (B) providing a spinning machine having an inlet that is operatively coupled to an expanded surface area extruder outlet; (C) using a pressure regulation system to reduce the pressure within the expanded surface area extruder; (D) passing a plurality of flakes comprising recycled PET through the expanded surface area extruder to at least partially melt the plurality of flakes to form a polymer melt; and (E) substantially immediately after passing the plurality of flakes through the expanded surface area extruder, using the spinning machine to form the polymer melt into bulked continuous carpet filament. In some embodiments, the method may include passing the plurality of flakes comprising recycled PET through a PET crystallizer prior to extrusion.

A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) washing a plurality of flakes of recycled PET; (B) providing a PET crystallizer; (C) after the step of washing the plurality of flakes, passing the plurality of flakes of recycled PET through the PET crystallizer; (D) at least partially melting the plurality of flakes into a polymer melt; (E) providing a multi-rotating screw (MRS) extruder having an MRS section; and a vacuum pump in communication with the MRS section; (F) using the vacuum pump to reduce a pressure within the MRS Section; (G) after the step of passing the plurality of flakes through the PET crystallizer, passing the polymer melt through the MRS Section; and (H) after the step of passing the polymer melt through the MRS extruder, forming the polymer melt into bulked continuous carpet filament.

Chopped fiber composite systems and methods are disclosed. Sorting systems include a conveyor, an imager, a plurality of receptacles, a pneumatic device, and controller. Molding systems include a conveyor, an imager, a mold, a pneumatic device, and a controller. The controller directs the pneumatic device to alter the freefall of chopped fiber composite pieces based on characteristics of the chopped fiber composite pieces as they drop from the conveyor and into a receptacle or a mold. Sorting and molding methods include dropping chopped fiber composite pieces, detecting characteristics of the dropping pieces, and directing the pieces based on the detected characteristics.

The present invention relates to a method of identifying and/or distinguishing materials by means of luminescence, wherein at least one luminescent substance is incorporated into the material and/or applied onto the material and the luminescence behaviour of the substance is analysed after excitation by means of radiation, and the use thereof for identifying and/or sorting and/or recycling and/or authenticating and/or performing a quality check and/or formulation check on materials.

Components of a system for marking, identification and segregation of plastic waste, including waste of multi-layer and multi-component plastics is disclosed herein. The coating material for marking plastics contains a base of the coating material and fluorescent markers dissolved or dispersed in the base of the coating material. The composition of the coating material or the way it is printed constitutes an arbitrary code, consistent with the adopted marking system. The coating material can be washed off from the surface of marked material with a washing agent. The code contained in the composition of the coating material or in the way it is printed is readable after irradiating with appropriate wavelength. The use of printed graphic or text patterns with at least two coating materials containing different fluorescent markers allows for creation of a practically unlimited number of individual identification codes.

A multi-layer coextruded film structure, particularly a multi-layer coextruded barrier film structure, for producing a recycle-ready packaging material, the multilayer coextruded film structure comprising at least two or more polymeric layers; wherein at least one of the polymeric layers comprises at least one fluorescent tracer that has an absorbance wavelength and an emission wavelength when exposed to ultra violet light; that provides a detectable fluorescence when exposed to ultra violet light at an absorbance wavelength in the range of from 100 nm to 400 nm; that provides an emission wavelength in the visible blue range of from 380 nm to 700 nm when exposed to ultra violet light, and that provides visible identification of recycle-ready packaging material made from the multi-layer film structure; and wherein the visible identification, in turn, provides the capability of sorting the recycle-ready packaging material from non-recycle-ready packaging materials; a process for producing the above multilayer film structure; and a multilayer recycle-ready barrier packaging article produced from the above multilayer film structure.

The invention relates to a method for separating waste polyurethane foams, wherein for each polyurethane sample (1) of a supply stream (2) comprising polyurethane samples (1) from waste at least one respective spectrum (3) is recorded, wherein the at least one respective spectrum (3) is recorded by near-infrared spectroscopy, wherein each polyurethane sample (1) of the supply stream (2) is classified by a classification algorithm (5), which classification algorithm (5) is based on machine learning, based on the respective at least one spectrum (3) into a respective class (8a-e) of at least two classes (8a-e), wherein the supply stream (2) comprising polyurethane samples (1) is separated into at least two streams (11a-e) according to the classification into the respective class (8a-e) and wherein each class (8a-e) corresponds to a type of polyurethane. The invention also relates to a system for separating waste polyurethane foams.

An efficient material recovery facility is disclosed, including: a first sorting device configured to: process a first instruction to remove a first target item from a set of items; and in response to the first instruction, perform a first sorting action to remove the first target item from the set of items, wherein the set of items excluding at least the first target item is to be transported towards a second sorting device, wherein the second sorting device is associated with a same sorting device type as the first sorting device; and wherein the second sorting device is configured to perform a second sorting action to remove a second target item from the set of items excluding at least the first target item in response to receiving a second instruction to remove the second target item.

The invention relates to the identification of polymer materials on the basis of the fluorescence decay time of the intrinsic fluorescence of the polymer materials for definite sorting in a completely separated manner. The invention further relates to marking with fluorescent dyes, which, because of the specific fluorescence decay times of the fluorescent dyes, can further increase the sorting reliability by means of redundancy and can be used to identify particular batches.

A method for recycling plastic such as plastic toys includes grinding the plastic into plastic pieces, sorting the plastic pieces based on type of plastic, sorting the plastic pieces based on colour, after sorting of the plastic pieces, shredding the sorted plastic pieces into plastic flakes, and processing the plastic flakes into a recycled good by means of rotational moulding. During the rotational moulding, a micronized plastic is added.