Thanks for the reply, Moose. Okay, I've done this twice now after reading through the link you posted some plus several other sources. Each test batch I wet with rubbing alcohol (70%), one very wet, one not so wet. I then screened the product. Each time I get fluffy, delicate granules. What I see is that it seems that the folks posting information about screening to form granules are using it for pyrotechnics which probably don't need to have the same durability as BP for firearms/cannons. That is, they won't be carrying it around a lot. It'll get put into a device and remain there until fired and probably not transported very much beforehand. This second batch I did, some I left caked and not screened. The screened stuff is fluffy crap but the cakes are hard. I am going to guess that back when BP was *the* propellant of war that they caked it and cracked it and sorted via screens. Even with 5% dextrin in the mix the stuff formed through the screen is not sturdy.