Partially oriented yarn (POY) generation using polyethylene terephthalate (PET) bottle flakes

1. A method comprising:

selecting Polyethylene Terephthalate (PET) flakes from bottles having an intrinsic viscosity ranging from 0.748 to 0.752, a b color value of <1.0 in accordance with an L, a, b color scale, an L color value of >60 in accordance with the L, a, b color scale, and a transparent appearance as a raw material;

charging the selected raw material into a crystallizer to generate a crystalline version thereof;

drying the crystalline version of the raw material with dehumidified air at a temperature of 160-180° C. and with a dew point of −40° C. to bring down a moisture level thereof below 100 parts per million (ppm);

melting the dried crystalline version of the raw material through an extruder having a temperature therein maintained at 285-295° C.;

feeding the melted raw material into a spin beam having a consistent temperature and a consistent pressure of the fed melted raw material maintained therein;

generating, through a spinneret associated with the spin beam, a plurality of filaments based on extruding, through the spinneret, the melted raw material fed into the spin beam;

forming a yarn based on combining the plurality of filaments extruded through the spinneret;

winding the formed yarn to generate a spool of Partially Oriented Yarn (POY); and

utilizing the generated spool of POY as another raw material to generate a Draw Texturized Yarn (DTY) having a denier of 50-500.

2. The method of claim 1 , wherein charging the selected raw material into the crystallizer comprises charging the selected raw material into a hopper associated therewith.

3. The method of claim 1 , further comprising passing the melted raw material through a filter capable of removing particles up to 40 microns in dimension prior to the feeding thereof into the spin beam.

4. The method of claim 1 , further comprising cooling the plurality of filaments out of the spinneret at a temperature of 7-12° C. in conjunction with the combination thereof to form the yarn.

5. The method of claim 1 , further comprising lubricating the plurality of filaments of the formed yarn using an oil applicator.

6. The method of claim 1 , further comprising:

loading the generated spool of POY into a DTY machine comprising at least one heater, a temperature of the at least one heater being 180-190° C.

7. The method of claim 6 , further comprising drawing the spool of POY through the at least one heater to generate the DTY having the denier of 50-500.

8. A method comprising:

selecting PET flakes from bottles having an intrinsic viscosity ranging from 0.748 to 0.752, a b color value of <1.0 in accordance with an L, a, b color scale, an L color value of >60 in accordance with the L, a, b color scale, and a transparent appearance as a raw material;

charging the selected raw material into a crystallizer to generate a crystalline version thereof;

drying the crystalline version of the raw material with dehumidified air at a temperature of 160-180° C. and with a dew point of −40° C. to bring down a moisture level thereof below 100 ppm;

melting the dried crystalline version of the raw material through an extruder having a temperature therein maintained at 285-295° C.;

feeding the melted raw material into a spin beam having a consistent temperature and a consistent pressure of the fed melted raw material maintained therein;

generating, through a plurality of spinnerets associated with the spin beam, a plurality of filaments through each spinneret based on extruding, through the each spinneret, the melted raw material fed into the spin beam;

forming a yarn based on combining the plurality of filaments extruded through the each spinneret with the plurality of filaments extruded through other spinnerets of the plurality of spinnerets;

winding the formed yarn to generate a spool of POY; and

utilizing the generated spool of POY as another raw material to generate a DTY having a denier of 50-500.

9. The method of claim 8 , wherein charging the selected raw material into the crystallizer comprises charging the selected raw material into a hopper associated therewith.

10. The method of claim 8 , further comprising passing the melted raw material through a filter capable of removing particles up to 40 microns in dimension prior to the feeding thereof into the spin beam.

11. The method of claim 8 , further comprising cooling the plurality of filaments out of the each spinneret at a temperature of 7-12° C. in conjunction with the combination thereof with the plurality of filaments out of the other spinnerets to form the yarn.

12. The method of claim 8 , further comprising lubricating the plurality of filaments of the formed yarn using an oil applicator.

13. The method of claim 8 , further comprising:

loading the generated spool of POY into a DTY machine comprising at least one heater, a temperature of the at least one heater being 180-190° C.

14. The method of claim 13 , further comprising drawing the spool of POY through the at least one heater to generate the DTY having the denier of 50-500.

15. A method comprising:

selecting PET flakes from bottles having an intrinsic viscosity ranging from 0.748 to 0.752, a b color value of <1.0 in accordance with an L, a, b color scale, an L color value of >60 in accordance with the L, a, b color scale, and a transparent appearance as a raw material;

charging the selected raw material into a crystallizer to generate a crystalline version thereof;

drying the crystalline version of the raw material with dehumidified air at a temperature of 160-180° C. and with a dew point of −40° C. to bring down a moisture level thereof below 100 ppm;

melting the dried crystalline version of the raw material through an extruder having a temperature therein maintained at 285-295° C.;

passing the melted raw material through a filter capable of removing particles up to 40 microns in dimension;

feeding the filtered and melted raw material into a spin beam having a consistent temperature and a consistent pressure of the fed filtered and melted raw material maintained therein;

generating, through a spinneret associated with the spin beam, a plurality of filaments based on extruding, through the spinneret, the filtered and melted raw material fed into the spin beam;

forming a yarn based on combining the plurality of filaments extruded through the spinneret; and

winding the formed yarn to generate a spool of POY; and

utilizing the generated spool of POY as another raw material to generate a DTY having a denier of 50-500.

16. The method of claim 15 , wherein charging the selected raw material into the crystallizer comprises charging the selected raw material into a hopper associated therewith.

17. The method of claim 15 , further comprising cooling the plurality of filaments out of the spinneret at a temperature of 7-12° C. in conjunction with the combination thereof to form the yarn.

18. The method of claim 15 , further comprising lubricating the plurality of filaments of the formed yarn using an oil applicator.

19. The method of claim 15 , further comprising:

loading the generated spool of POY into a DTY machine comprising at least one heater, a temperature of the at least one heater being 180-190° C.

20. The method of claim 19 , further comprising drawing the spool of POY through the at least one heater to generate the DTY having the denier of 50-500.