Metal injection moulding (MIM) is an innovative injection moulding technique widely used to produce complex shaped components from feedstock composed of metal powders and thermosetting or thermoplastic binders. In MIM, binder selection and formulation are considered as critical processes since binder characteristics dictate the success of MIM. The purpose of this study is to determine the feasibility of polyvinyl butyryl (PVB) based binder system in Ti-6Al-4V(wt.%)/binder feedstock, as well as to understand the effects of key parameters, such as powder loading and mixing conditions on the rheological properties of a feedstock. In this study, PVB, polyethylene glycol (PEG), and stearic acid (SA) were chosen to formulate a multi-component binder system to prepare Ti-6Al-4V based feedstock with the aid of three types of mixers: a compounder, a modified mechanical mixer and a twin screw extruder. Further, morphological analysis was performed using optical microscopy and scanning electron microscopy. Thermal analysis was performed using simultaneous differential thermal analysis and thermogravimetric analysis. Results showed that binder formulation was reasonably successful with the aid of both mechanical mixer and a twin screw extruder under certain mixing conditions, and the critical powder loading was 68 vol.%, resulting in an optimum powder loading of 63 vol.%.