A method of manufacturing a plurality of colors of bulked continuous carpet filament from a single multi-screw extruder which, in various embodiments, comprises: (A) passing PET through an extruder that melts the PET and purifies the resulting PET polymer melt; (B) adding a liquid colorant to the polymer melt using a liquid metering system; (C) using one or more static mixers (e.g., up to forty static mixers) to substantially uniformly mix (e.g., homogeneously mix) the polymer melt and the liquid colorant; and (D) feed the uniformly mixed and colored polymer melt into a spinning machines that turns the polymer into filament for use in manufacturing carpet, rugs, and other products.

Continuous compounding systems include a feeding section and a compounding section. Method for compounding or mixing solid matter and liquid matter include providing a continuous compounding system, adding matter to the continuous compounding system, and mixing or compounding the matter.

A method for producing a stabilizer composition for a polymer, particularly a polymer containing halogen such as polyvinyl chloride, in which components for forming the stabilizer composition are mixed in an extruder and continuously discharged therefrom, in which an impact modifier is admixed. A correspondingly produced stabilizer composition and the use of a planetary roller extruder to produce a stabilizer composition.

A method for producing a stabilizer composition for a polymer, particularly a polymer containing halogen such as polyvinyl chloride, in which components for forming the stabilizer composition are mixed in an extruder and continuously discharged therefrom, in which an impact modifier is admixed. A correspondingly produced stabilizer composition and the use of a planetary roller extruder to produce a stabilizer composition.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 25 millibars, or another predetermined pressure. The streams are recombined into a single polymer stream. Polymer from the polymer stream is then formed into bulked continuous carpet filament.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 25 millibars, or another predetermined pressure. The streams are recombined into a single polymer stream. Polymer from the polymer stream is then formed into bulked continuous carpet filament.

A process for the continuous production of cured rubber membrane, the process comprising (i) preparing a continuous stream of curable rubber composition; (ii) forming the continuous stream of curable rubber composition into a continuous green-rubber extrudate; (iii) curing the continuous green-rubber extrudate to form a continuous cured membrane; and (iv) fabricating the continuous cured membrane into rolls of cured membrane, where the curable rubber composition is characterized by at least one of a t90 at 190? C. of from about 1 to about 12 minutes and a T5 at 135? C. of from about 5 to about 20 minutes.

A process for the continuous production of cured rubber membrane, the process comprising (i) preparing a continuous stream of curable rubber composition; (ii) forming the continuous stream of curable rubber composition into a continuous green-rubber extrudate; (iii) curing the continuous green-rubber extrudate to form a continuous cured membrane; and (iv) fabricating the continuous cured membrane into rolls of cured membrane, where the curable rubber composition is characterized by at least one of a t90 at 190? C. of from about 1 to about 12 minutes and a T5 at 135? C. of from about 5 to about 20 minutes.

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 expanded surface area extruder while maintaining a pressure within the expanded surface area extruder below about 25 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.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 5 millibars. The streams are recombined into a single polymer stream and formed into bulked continuous carpet filament.