With the development of a silica-loaded free-flowing rubber/filler compound system based on E-SBR it could be demonstrated that the powder rubber technology can also be successfully used for white fillers. For this, the addition of bi-functional sulphur-containing organosilanes for rendering the silica surface hydrophobic plays a vital role. During drying of the powder rubber, a reaction between the filler and silane takes place with the evolution of ethanol whereby the presence of a completely silanized silica in the final product can be shown. Starting from a suitable raw material selection, a focal point of the paper is the manufacture and characterization of the products. Further, the handling of the products in today's internal mixer process is described and special attention is given to the quantitative determination of the composition of the released waste gases. Finally, the in-rubber data are shown in comparison with the reference compounds produced by conventional methods. In particular, investigations for the reduction of the mixing time and number of mixing stages as well as for blending of various PR products are presented and discussed.