Abstract: A continuous carpet (10) or other flooring manufacturing process that accommodates use of a variety of materials including recycled PVC from used carpet and carpet manufacturing waste. The continuous process forms backing (12) and is capable of feeding the backing into a lamination stage for bonding with the face cloth (14). By providing a continuous process whereby the backing layer, upon formation, can be immediately laminated to the face cloth, manufacturing time and associated cost are reduced. Moreover, formation of the backing layer as a process separate from the lamination thereby protecting the face cloth from unnecessary heat and pressure and enhancing the many types of material, including recycled and waste materials, especially used carpet and used carpet by products. Use of these cheaper materials reduces both the manufacturing cost by products.