Methods for manufacturing bulked continuous filament

A method of manufacturing bulked continuous carpet filament, the method comprising:

• separating a polymer melt into at least eight streams such that each of the at least eight stream is at least partially exposed to a chamber pressure within a chamber of less than about 5 millibars;
• after the at least eight streams are exposed to the chamber pressure of less than about 5 millibars, recombining the at least eight streams into a single polymer stream;
• and
• forming polymer from the single polymer stream into bulked continuous carpet filament.

A method for manufacturing bulked continuous carpet filament, the method comprising:

• providing a pressure regulation system;
• using the pressure regulation system to reduce a chamber pressure within a chamber to below about 5 millibars;
• after using the pressure regulation system to reduce the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber;
• increasing a surface area of the polymer melt exposed to an interior of the chamber utilizing at least eight different streams of the polymer melt;
• while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars;
• after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream;
• and
• forming polymer from the single polymer stream into bulked continuous carpet filament.