The challenge of reusing scrap rubber material is mainly due to its crosslinked/vulcanized structure, which prevents the material from melting and from being melt processed into new items. The most feasible recycling approach is believed to be a process in which the vulcanized rubber is first pulverized into a fine powder and then incorporated into new products. Solid state shear extrusion (SSSE), developed at Illinois Institute of Technology, is a process for continuous pulverization of rubber materials into a fine powder (Aratoopour, H. U.S. Pat. 5,704,555 (1998); Arastoopour, H.; Schocke, D. A.; Bernstein, B.; Bilgili, E. U.S. Pat. 5,904,885 (1999); Ivanov, G. Polym Eng Sci 2000, 40, 676). In this work, the design of the SSSE apparatus was modified to overcome heat generation due to pulverization and the limitation from the torque/feeding rate relation and, thus, to increase the efficiency of the process in the production of finer particles at higher throughput. The modification was achieved by separating the original process into the extrusion section and the pulverization section. The extrusion section is dedicated to convey material to the pulverization section, which consists of a cylindrical housing and a rotatable cylindrical element that rotates independent of the extruder's screw. The rotatable cylindrical element can be treaded or flightless. Both sections are connected with an adapter. This new approach to the design allowed us to apply a more efficient cooling system, capable of removing the heat of pulverization and, in turn, results in the production of finer rubber particles. Furthermore, separation of the conveying process from the pulverization process resulted in a reduction in extruder's torque and a significant increase in the throughput. (c) 2006 Wiley Periodicals, Inc.