The recycling of aluminium chips by direct processing of the chips in the extrusion process is a metal forming technique which requires less energy than remelting of the chips and prevents further material losses during the remelting process. For this purpose, chips contaminated with lubricant or cleaned chips can be used for the chip-based extrusion. Since the process parameters also influence each other and, in addition, the properties of the chips must be considered as additional parameters, which also have an influence on the success of the process and the quality of the profiles the determination of the factors influencing the process has not yet been completed. Due to previous investigations, it can be determined that the quality of the extruded profiles depends on the choice of the tool concept as well as the extrusion ratio. In contrast to previous studies investigating the influence of die design, chip geometry and compaction route, a porthole die was used in the present experiments. In these experiments, the process parameters such as extrusion speed, temperature, homogenization time were varied and their influence on the mechanical properties was evaluated. Furthermore, a new criterion is presented to evaluate the welding quality of the chips. In experimental as well as numerical investigations, the use of tensile tests and the evaluation of the weld quality showed that the mechanical properties of the profile vary over the cross-section independently of the process parameters. At the same time, the results have shown that in extrusion of chip-based billets, the yield strength, tensile strength and breaking elongation can be significantly influenced by the use of appropriate process parameters.