The flash-evaporation process is a promising technique in the domain of the large scale production of ultra-fine particles. By means of a common hollow cone nozzle, superheated solutions are steadily sprayed into an evacuated atomization chamber where the solvent evaporates and the solute crystallizes. Separation of the particles from the aerosol is achieved by axial cyclones in a parallel arrangement. A continuous operating pilot plant, from the size of a desk, already produces up to 3 g/h of a product with a particle size below 500 nm. The thermodynamic properties of this process are advantageous for the nanostructuration of various organic compounds such as primary and secondary explosives as well as energetic composites. (C) 2012 Elsevier B.V. All rights reserved.