AbstractThe synthesis of many thermoplastic and elastomeric polymers can be accomplished by dispersing the monomer (or a blend of monomers) to be polymerized in water with the aid of various surfactants. The monomer is then polymerized by the introduction of a free radical catalyst to produce a latex of the polymer. Coagulation is the first step in isolating the polymer from the latex, and typically, many subsequent process steps are required to “finish” the polymer to the pelletized or expanded crumb from suitable for end users to convert the polymer into useful products.The process described herein combines all the process steps required to coagulate, separate and dewater, wash, devolatilize, homogenize and pump the polymer in a single‐step, short residence time system. The machine employed for this process is a counter‐rotating, tangentially opposed twin‐screw extruder. One important variation of the basic process combines an integral plasticating extrusion step with the latex conversion to make polymer blends and alloys. Critical process parameters are identified and discussed and examples of pilot plant scale experimental data for ABS (acrylonitrile‐butadiene‐styrene terpolymer) systems