Patent ID: 8017662

Claim:
A process for producing a synthetic fiber composition, comprising i. shaving face yarn from post consumer carpet by use of a shaving device to provide a shaved face yarn; ii. reducing the sizes of said shaved face yarn; iii. agitating said shaved face yarn; iv. removing contaminants from said shaved face yarn by mechanical screening, washing, or a combination thereof; and v. melt filtering of said shaved face yarn to produce a recycled fiber-forming thermoplastic resin; and vi. blending at least 2 weight percent of said recycled fiber-forming thermoplastic resin with a virgin fiber-forming resin to form a fiber-forming blend, wherein said fiber-forming blend provides a pressure rise of 0.6 psi/gm or less when said blend (i) contains 2 weight percent of said recycled fiber-forming thermoplastic resin and (ii) is subjected to a melt filter test using a Dutch twilled weave filter screen of 80×700 nominal mesh count using a pilot-scale single screw extruder.