A new and novel continuous mixer for rubber compounds has been developed in a co-operation between the Rubber Process Engineering Centre at Loughborough University and Carter Bros (Rochdale) Ltd. The mixing conditions can be adjusted over a wide range from the control panel to suit the rubber compound, with the aim of combining the versatility of the internal mixer with the inherent energy efficiency and consistency of a continuous system. The new mixer comprises two main elements, a compactor/feeder and a single-rotor mixing unit. In the compactor/feeder a particulate pre-blend is converted to a continuum (the incorporation stage) and is then metered the mixing unit, where it is subjected first to distributive mixing and subsequently to dispersive mixing. Separation of the distributive and dispersive mixing functions allows the latter to be optimised to apply local, high intensity stresses to the rubber compound. A prototype with a maximum output of 150 kg/h has been built. Results to date confirm that a low rubber temperature in combination with good filler dispersion and energy efficiency is attainable.