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In powder processing, fouling is a serious and common issue. This is caused by powder adhesion on processing surfaces, leading to clogging and disruption. Most of the time, powder adhesion is due to triboelectric charging. Electrostatically charged powder adheres to surfaces, accumulating and eventually leading to blockage of channels (e.g., transfer pipes, etc.). This production problem is usually discovered during manufacturing scale‐up. The characteristics of the powder correlate with the extent of triboelectric charging, and thus it is possible to predict this production problem during the product formulation/development stage. A case study to predict and prevent fouling for 3‐in‐1 coffee powder and its components (sugar, coffee, and creamer) was investigated. First, the electrostatic charge of the commercial 3‐in‐1 coffee mixes and their individual ingredients were measured. Analytical tests were also …