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 flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 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 making a die body configured to extrude a honeycomb body, the method comprising the step (I) of manufacturing a die body and the step (II) of predetermining an upstream slot width W1 of the die body such that the upstream slot width W1 is optimized while a root of each die pin includes a section modulus within a predetermined section modulus range. The method still further comprises the step (III) of predetermining a slot length L such that a pin stress is within a predetermined pin stress range.

A method of recycling PET into PET nurdles, 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 18 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 PET nurdles. In various embodiments, the polymer melt is formed into PET nurdles using any suitable technique such as, for example, any suitable strand pelletizing or melt pelletizing techniques.

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 flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 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.

The invention relates to an apparatus and a process for producing pigment-containing, in particular carbon-black-containing, polymer mixtures comprising polycarbonates and optionally elastomers, and/or other components, where the mouldings produced therefrom have, after the shaping process via injection moulding or via extrusion, improved surface properties and improved mechanical properties.

A method for directly preparing a foamed polylactic acid (PLA) product from a PLA melt includes PLA melt preparation, feeding, and two-stage extrusion. In the two-stage extrusion, a pressure at an outlet of a first-stage twin-screw extruder is 15 MPa to 17 MPa, a PLA melt is fed at a rate of 250 kg/h, a foaming additive is fed at a rate of 7.5 kg/h to 10 kg/h, and a foaming gas is fed at a rate of 2.8 L/h to 7.5 L/h. The method can ensure both foamability and quality of a material and reduce more than of energy consumption; and an obtained product has an adjustable foaming rate of 3 to 25, a crystallinity of 40.3% to 48.5%, a tensile strength of 8.7 MPa to 19.6 MPa, and an apparent density of 0.05 g/cm.sup.3 to 0.4 g/cm.sup.3.