A systematic approach to deal with the operational issues in solids processing plants is presented. Potential problems in various equipment units are identified and classified according to continuum-scale phenomena: breakage, adhesion and cohesion, compaction, bulk solids flow problems, fluid-driven solids flow problems, and segregation. Analysis is performed in the continuum and particle scales so as to identify the causal and opposing effects of each problem. With appropriate mathematical models and empirical correlations, these effects can be related to equipment design, operating conditions, particle attributes, and material properties. The ratio of these competing effects shows whether a potential problem is a real concern and points the direction for taking preventive measures. The action plan may include changing operating conditions or equipment design of a particular unit, or, making modifications to upstream equipment units. The method is illustrated with an industrial example: the production of potash.