Polyester carpet yarn is heat set during the production process in order to impart structural stability. Although batch (autoclave) and continuous (Superba TVP and Suessen GVA ) heat setting methods are used, the continuous processes are prevalent and constitute a greater part of this study. Commercial heat setting equipment and settings are used here because previous works were the results of laboratory studies. The primary technique applied in this study to determine the microstructural features of polyester is x-ray diffraction. Crystallization and crystallite melting temperatures from differential thermal analysis ( DTA ) and colorimetric determinations of initial rates of dyeing are also measured to provide additional data for interpreting the results, and tensile properties of the yarns are reported as well.X-ray and DTA results indicate no significant increases in the degree of crystallinity of yarns heat set by the Superba TVP method, while crystallinity increases with increasing temperature for samples heat set by the Suessen GVA method. Crystal size increases for samples heat set by either of the continuous methods. Although x-ray determined crystallinity measures are significantly different at different levels of temperature and dwell time, there are no significant differences in heat of fusion values obtained from DTA with changes in heat setting temperatures and dwell times. Tenacity, percent elongation, and work to break increase as a result of heat setting for samples set using the Superba TVP, autoclave, or Suessen GVA equipment, while the initial modulus decreases compared to a non-heat set sample.Heat setting is an important step in carpet yam production, helping to stabilize the yarns to maintain their twist, bulk, crimp, and strength characteristics [ 21 ] . Yam stability is necessary for subsequent processing and future performance in carpet wear [ 5,27]. The majority of past research dealing with the heat setting of polyester and nylon yarn, usually filament yarn, has been done under laboratory conditions. In this work, we include the commercial heat setting of spun polyester carpet yam using the Superba TVP machine, built by Superba SA of France, the Suessen GVA machine, manufactured by Hoerauf-Suessen of Germany, and a Gaston County autoclave. Although the more economical continuous methods for heat setting carpet yams are in greater use today, we did some testing of autoclaved yarns as an ancillary study because the autoclave was used for heat setting before the development of continuous methods. Our results, at times, differ from those of the laboratory studies.The autoclave provides a batch method for heat setting yarns [ 21 ] . Skeins are bulked and heat set during repetitive cycles of various temperatures and pressures.When skeins are tumbled in the presence of steam, the yarn is bulked to a greater degree than in either of the two continuous procedures, but heat transfer to some parts of the skein is not uniform and the continuous methods can provide more even penetration of heat and...