Particle size distribution (PSD) is often specified in product design and can have a significant impact on plant operations. To meet the target PSE, a four-step procedure is proposed. For the desired PSD, a functional structure that identifies the required changes to the particles is constructed. Then, specific equipment as well as recycle streams are identified. Finally, alternative processes are evaluated using discretized population equations to determine process feasibility and to select the best option. The procedure is illustrated with three examples-the production of salt, alumina, and metronidazole tablets.