Abstract: The present disclosure relates to a process of preparing an elastomer composite in an extruder, said process comprising: (a) providing at least one solid particulate ingredient in a first mixing zone to obtain a first mix; (b) providing at least one elastomer in a second mixing zone to obtain a second mix; (c) contacting the first mix and the second mix to obtain a third mix; and (d) processing the third mix to obtain an elastomer composite, wherein the first mixing zone and the second mixing zone has a temperature in the range of 30° C.-50° C., the processing of the third mix is carried out at a temperature in the range of 100° C.-250° C. The present disclosure also relates to a formulation comprising an elastomer composite produced by the process as disclosed herein.