A study has been performed to examine the process of micropelletization on four different polyethylenes with melt index values between 1 and 5 g/10 min. The experiments were done on a 50-mm 30:1 L/D extruder with an underwater micropelletizer attached. The average micropellet size that was produced ranged from 0.4 to 0.5 mm in diameter depending on whether a plastomer or high-density grade was selected. The dimensions of the pellets were influenced strongly by the occurrence of die-hole freeze-off. Minor sharkskin was observed on the surface of the micropellets, a result of the high stresses experienced in the pelletizer die. A non-isothermal, axisymmetric flow model was used to assist in the analysis by comparing the observed results to the predicted shear stresses in the die. The calculations revealed that extremely high shear rates were present in the die holes, resulting in a significant degree of wall slip. The measured rheological properties of the micropellets did not show any change in comparison to their virgin resins, likely because of the presence of wall slippage and the short residence time of the polymer in the die holes. (C) 2004 Society of Plastics Engineers.