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In recent years, near infrared (NIR) spectroscopy has become an analytical tool frequently used in many chemical production processes. In particular, on-line measurements are of interest to increase process stability and to document constant product quality. Application to polymer processing e.g. polymer extrusion, could even increase product quality. Interesting parameters are composition of the processed polymer, moisture, or reaction status in reactive extrusion. For this issue a transmission sensor was developed for application of NIR spectroscopy to extrusion processes. This sensor includes fibre optic probes and a measuring cell to be adapted to various extruders for in-line measurements. In contrast to infrared sensors, it only uses optical quartz components. Extrusion processes at temperatures up to 300°C and pressures up to 37 MPa have been investigated. Application of multivariate data analysis (e.g …