A systematic procedure for the synthesis of bulk solids processing systems guides the user in an evolutionary manner to generate flowsheet alternatives to transform a solids feed with given attributes into products with desired attributes. The first step is to select a functional structure based on the primary objective of the processing system. This is followed by the selection of equipment for the functional structure. In the third step, the functional structure is expanded by adding other necessary unit operations to form a flowsheet. This is accompanied by the assignment of a suitable equipment unit to each unit operation. Storage and transportation units are then added to the flowsheet in the fourth step. Rules and heuristics to help make decisions at each step are presented, as well as simulations used to evaluate flowsheet alternatives. Design variables are identified and short-cut models based on discretized population balance equations are used to quantify equipment performance. The procedure is illustrated with commercial examples including the production of potash, pesticide granules aspirin and an azo dye.