For example, on the top level or the fourth level of the machine, the raw white polymer and colored pellets are carefully mixed to achieve the correct color.

On the third level, this mixture is actually prepared for the extrusion process. On the the second level the first formation of the fiber takes place. Finally on the lowest level the yarn is finished and packaged ready for the tufting machine. The white polymer and colored pellets are brought to the top level and fed into this blending apparatus. Very precise amounts of white and colored pellets are automatically weighed and then mixed together to produce a consistent finished color in the yarn.

The colored pellets, the raw white polymer and possibly another color or fiber additive that is needed for some special use. Small amounts of these materials are automatically weighed and then dropped down the tube into the next level of the extrusion plant. When they drop down to the next level they go into the second mixing hopper and finally to a smaller holding tank before entering into the actual extruder. The extruder is really a large heated screw.

It's principal of operation is similar to grinding sausage meat except that the extruder is much larger and is heated. As the pellets progress down the bottle of the extruder they are mixed even further and during this process they are melted.

The temperature is very carefully controlled. The colored liquid polymer is processed through a series of filters before moving down to the actual extrusion operation. The cabinets are opened, so you see the BCF yarn being formed.

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