In this work, the strength of tablets made from mixtures of whey protein concentrate (WPC) powder and different types of sugar was investigated. The agglomerated WPC powder was pneumatically conveyed (lean phase) at three different air speeds of 10, 20 or 30 m/s to simulate the effects of industrial powder transport, resulting in agglomerates with reduced integrity. Conveyed and control WPC powder, and sugar of three different particle size distributions (i.e., granulated, GS; caster, CS and icing sugar, IS) were analysed for microstructure, particle size, moisture, and flowability. Tensile strength of tablets from WPC powder alone or blended with 0.5-10% sugar was tested. Conveying of WPC powder led to a significant increase in tablet strength, (i.e., from failure strength of 1.67 N/mm(2) for control tablets to 2.33, 2.11 and 2.11 N/mm(2) after conveying at 10, 20 or 30 m/s, respectively), suggesting that the generation of smaller powder particles led to increased mechanical strength of tablets. The addition of sugar also resulted in a significant increase in tablet strength (e.g., failure strength of 2.34, 2.12 and 2.47 N/mm(2) at 1.5% addition level of GS, CS and IS, respectively) and strongest tablets were obtained at 1.5-3% sugar addition and by blending with icing sugar. This study demonstrated, for the first time, that conveying and dry blending of whey protein and sugar powders significantly influenced the rheological properties of resultant tablets.