The characteristics of powder coatings manufactured through a novel processing technique based on nonisothermal Nlow-induced phase inversion granulation enhanced by fluid injection to promote phase inversion and particle formation from melt state is summarized. Experiments were carried out in a purpose-built granulator, which operates in a parallel disk rotor-stator arrangement, so that the mechanism of granulation could be studied. The product of this intensive granulation was compared with that of the conventional powder coating manufacturing process. Understanding the mechanism of intensive granulation helped to redesign the equipment that resulted in smaller particles. Pigment dispersion characteristics were improved by intensive granulation. Also, the particle size span can be significantly reduced by dry granulation and gas-phase granulation, and the flowability can be improved by wet granulation. Chemical analysis of particles by Fourier transform infrared spectroscopic analysis showed that the injection of coolant fluid had no effect on the chemical composition. (C) 2011 American Institute of Chemical Engineers AIChE J, 2012