Abstract: Process and apparatus for forming essentially spherical solid pellets directly from a melt, and particularly solid metal pellets such as iron and lead. The melt from a column of a preset height is directed through one or more orifices in a way to form a jet which experiences an upwardly directed trajectory path and which under the influence of vibratory action breaks up to form pellets of a predetermined diameter. Adjustments of the column height and/or vibration frequency are used to control pellet diameter. The pellets may be formed and solidified in a controlled atmosphere; and in the case of iron pellets, the carbon content of the pellets may be adjusted, to attain a desired degree of hardness, either before or after pellet formation. Iron pellets thus formed are particularly suitable as substitutes for lead pellets in ammunition.