Abstract: In one embodiment, the method for recycling carpet can comprise decreasing an average size of the recycle carpet to form a processed carpet, wherein a bulk density of the recycle carpet is changed by less than or equal to about 15% during the decreasing. The processed carpet can be shear mixed and melted to form a melt ribbon which can be processed in a vented extruder to form an extrudate. Optionally, the extrudate can be pelletized.

Abstract: Disclosed herein are methods for recycling carpet, for making articles with the recycled carpet, and articles made therefrom. In one embodiment, the method for recycling carpet comprises: melting recycle carpet; reducing a water content of the recycle carpet to less than or equal to about 0.5 wt %, based upon the total weight of the recycle carpet and the water, to form a melt ribbon; and forming pellets from the extruded melt ribbon of recycle material.