In this century, waste of all types will be one of the biggest challenges facing man. Synthetic carpets will only account for a small but significant portion of this waste. By and large, the biggest quantity of waste in newly processed carpet occurs during shearing with an average waste of up to 20% or more. Incineration to recover energy, re-use in alternative forms and mechanical and chemical recycling are the current methods of tackling carpet waste in developed countries. On the contrary, no serious measures are taken to tackle carpet waste in Iran. Carpets made from acrylic carpet yarns as piles account for the majority of all carpets produced in Iran. Acrylic fibers are relatively expensive due to their high cost spinning methods. As mentioned above, shearing carpet produces the biggest amount of this valuable waste which finds its end-use as fillings or may be dumped into landfills in this country. In this work an attempt was made to introduce a method to re-use fully acrylic carpet shearing waste by dissolving it in DMF as the solvent and producing film yarn by dry-jet wet spinning. Recycling process discussed in this work consists of three steps: effective washing to remove spinning oil from waste fibers, preparation of different dope concentrations and spinning film yarn. At the outset, in order to study physical properties of produced film yarns from different dope concentrations a pilot plant was required so it was decided to modify the existing wet/dry-jet wet spinning pilot plant in the department. The evolution steps consist of: suitable spinneret devising, installation of digital thermal controlling system for coagulation bath, installation of thermal controlling system for extrusion cylinder, load transfer system optimization. Final film yarn was formed and stretched at the same bath. Acrylic film yarns as discussed in this work were not previously produced in Iran.