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Segregation occurs during most particulate materials-related unit operations including mixing, conveying, discharging, filling, and compaction. A redesigned, second generation primary segregation shear cell was fabricated to simulate and quantify the percolation and sieving mechanisms-based segregation. Several binary mixtures were tested to quantify the effect of size ratios, absolute size, and different constituents. In powder handling process, a mixture usually is comprised of different constituents. The constituents of binary mixtures studied were spherical shaped glass beads and irregular shaped poultry feed particles. The glass beads were considered as an ideal material whereas mashed poultry feed was considered as real-world material. Three binary size ratios 4:1, 6:1, and 8:1 were tested. For a given size ratio, three different absolute coarse (710-850, 1000-1200, and 1400-1700 m) to fine particle sizes were studied. Three key conclusions were drawn based on the PSSC-II test results: 1) The higher density and smoother surface of fine component of a binary mixture, the higher is the segregation potential. 2) The coarse particle shape effect, i.e., the irregular shaped coarse particles or higher porosity of coarse component of a binary mixture lead to higher segregation potential. 3) The fine particle properties play a major role in determination of the segregation potential of a binary mixture. The fine particle properties, to a certain extent, determine the particle size-related effects such as absolute size and size ratios, i.e., if fine particle properties of a binary mixture change, the size-related effect on segregation potential would definitely change.