Twin-screw extruders are operated with sequential filled and partially filled regions in order to perform the required unit processes. Channel fill length, defined as the length of fully filled regions in an extrusion screw, is gaining importance as a design parameter because of its implications on residence time distribution, distributive and dispersive mixing, and also process stability. A detailed study-experimental and theoretical-of the behavior of fill lengths in response to operating conditions (throughput, screw speed) and screw geometry is presented in this paper. Mean residence times were also measured for each geometry and operating condition. The apparatus consisted of a non-intermeshing counter-rotating twin-screw extruder (NITSE) with a transparent (acrylic) barrel, fed with corn syrup (Newtonian at room temperature). Fill length exhibits a nonlinear relationship with specific throughput (Q/N), with the slope increasing monotonously as the throughput Q increases at a given screw speed N. The mean residence time exhibits a strong linear relationship with inverse specific throughput and inverse fill length. A theoretical model was developed to predict the filled length based on pressure-throughput relationships taken from literature for this system, and the predictions were found to agree very well with experimental observations.