Abstract: The invention provides methods and apparatus for quantitatively measuring and controlling the quality of the dispersion of filler particles in rubber compounds. A magnified image of a section of a freshly cut surface of a processed rubber sample is captured by the digital board of a computer image processing system. Processing of the image uses a series of groups of computer commands including commands for enhancing the image, distinguishing the filler particle entities from the polymer matrix, defining and labeling the particle entities and displaying the results of the analysis of the image.

Abstract: A simple and efficient process and automated system is provided for controlling the mixing of polymeric material and additive materials in an internal mixer to provide quality products and batch to batch product uniformity. Real time mixing temperature profiles of a plurality of good quality batches of the same product are developed. The profiles are then superimposed or averaged to produce a real time temperature curve with maximum and minimum temperature tolerance limits, thus providing a range of batch temperatures that are allowable in real time during the mixing cycle. A process control system is programmed to store the range of allowable temperatures and to signal a mixer control to change at least one of the rotor speed and the ram pressure when the real time batch temperature falls outside the reference temperature range for a predetermined period of time.