Spray drying as a primary powder synthesis tool is not designed to separate particles during the process. Here we report on the simulation, optimization, and development of a customized multi-bin cyclone fora lab-scale spray dryer to segregate particles based on their sizes. Two criteria were chosen to optimize the number of bins, cutoff size, and pressure drop. Accordingly, a non-dimensional factor describing cyclone performance was introduced by investigating which five bins of powder collection were found to render a compromise between competing factors. Spray-dried powders were administered to the cyclone, and deposition of the particles in the bins was recorded. The cyclone could segregate particles with a size resolution as low as 4 pm. For each bin, the data on particle size, morphology, pore attributes, BET surface, and moisture content showed that even within a single batch, there is a broad span of particle properties. (C) 2020 Elsevier B.V. All rights reserved.