Polymer processing using extrusion has been widely used in industries because of the compounding capabilities of the extruders. The properties of the existing base polymers could be improvised by compounding with additives rather than the need to fabricate new base polymers. The mixing of input materials in the extruder is extremely critical to produce superior quality products. Quantification of stress history in the extruder could be used to understand the mixing behavior within the extruder. Residence Stress Distribution (RSD) is a methodology that was implemented to quantify the amount of material that undergoes a particular amount of stress within the Twin Screw Extruder (TSE). Percent Break-Up is a metric that was developed using RSD Methodology to compare the stress history experienced by polymer melts within the TSE with varying operating conditions (screw speed (N), specific throughput (Q/N). Experiments carried out using the UMD RSD methodology suggested that percent break-up (%BU) is a function of N and Q/N. In order to validate the findings of the RSD Experiments, 1-Dimensional Computer Simulation called Ludovic is used. Ludovic provides an insight into the behavior observed on performing the RSD experiment, as it helps correlate the internal behavior of the extruder i.e. shear rate, temperature, viscosity profile within the extruder, to the RSD results. The results obtained from the experiments are statistically analyzed using JMP to predict the influence of the operating conditions (N, Q/N) on the properties of the polymer melt (temperature, pressure, residence time etc.). Similarly, properties such as degree of fill in the screw channel are analyzed using the computer simulations and used to explain the internal behavior of the extruder.