Optimization of rotor speed based on stretching, efficiency, and viscous heating in nonintermeshing internal batch mixer has been investigated using polymer melt. A practical optimization technique was followed for optimization. Four different rotor speeds were used and characterized numerically with viscous dissipation and stretching. The heat distribution between rotor edge and mixer wall was calculated. Stretching experienced by the fluid was analyzed and the result was verified experimentally using particle tracking method. Exponential increase of energy dissipation between the rotor edge and the barrel at higher speed highlighted the importance of choosing the thermal properties of the polymer to avoid thermal degradation. (C) 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 127: 2739-2748, 2013