One of the main attributes of powders is flowability. Dry materials with a similar particle structure flow more easily than powders of different shapes. However, size is also an important variable in industrial powder handling.

Flowability decreases with the particle size as powders display greater cohesion and internal friction the smaller they become. To prevent ratholes or bridging and facilitate flow, advanced manufacturing equipment applies anti-clogging systems. These powder processing systems and techniques are designed to move fine to ultra-fine bulk in specialized powder applications from pharmaceuticals to food to cosmetics.

Mineral and metal powders present unique challenges in terms of processing, particularly when they are comminuted to finer materials. Particles become harder as their surface area increases, making them more challenging to densify.

Ductile metals like aluminum and copper retain plastic deformation properties down to particle sizes of 50-100 nanometers. But beyond that, powders need to be subjected to high temperatures to be effectively compacted.