In recent years, the world of powder processing has undergone significant changes. With more stringent regulations, rising labour costs and international pressures, there has never been a greater emphasis on production efficiency. Those companies who can produce faster and cheaper without compromising quality will be the ones that thrive. But with more markets demanding smaller volumes of more diversified products, manufacturers know that a process needs to be flexible as well as efficient. Companies cannot afford to overproduce products and hold excess inventories to meet varying demand. As a result, philosophies like ‘lean manufacturing’ are being viewed less as a trend and more as the essential method to follow. In this article, we explore how maximising mixer effectiveness using lean production principles is a springboard to more competitive powder processing.