Abstract: A method of manufacturing xerographic toner to achieve upper and lower particle size classification by first grinding large pellets of toner material in a jet mill. Upper particle size classification is achieved by then passing the ground material to a coarse classifier which operates to return relatively large particles to the jet mill for further grinding, and supplies the finer particles, which are generally no larger than 13 to 15 microns in diameter, to a cyclone separator. In the cyclone separator, the length of the cyclone's exit duct is controlled to achieve lower particle size classification by causing particles below a generally 5 micron diameter size to exit the separator as waste material by way of its upper exit duct. The finished product exits the cyclone by way of the cyclone's lower output port.