Handling cohesive, fine, or abrasive powders often leads to costly process disruptions — from hopper blockages to uneven dosing and excessive equipment wear. At Fraunhofer IWM, we combine advanced laboratory characterization of powder flow properties with high-fidelity DEM simulations to predict and optimize powder behavior in real process equipment. Our measurement-calibrated digital twins enable virtual prototyping and troubleshooting, significantly reducing trial-and-error on the shop floor. In this talk, we demonstrate how this integrated approach helps engineers design robust processes for even the most challenging bulk solids.