BACKGROUND People brew tea to drink an infusion that only contains 25% water-soluble constituents, leading to most of the insoluble materials being wasted. Tea powder could be drunk directly by mixing with water without producing any waste. Tea powder can also be used as a natural additive to improve the flavour and taste in beverages and foods. Much detailed information on the particle properties of tea powder is required with its increasing consumption. The aim of this study was to investigate the effects of particle size ranging from median diameter D-50 = 4.32 to 26.59 mu m on the composition, physical, rheological, and bioactive properties of black tea powder. RESULTS The results indicate that large powder sizes had high bulk density and flowability, whereas small powder sizes possessed good swelling ability and wettability. The contents of water extract, total polyphenols, crude fibre, catechins, and thearubigins reduced with a decrease in particle size. To change the particle size and concentration could adjust the elastic modulus and the viscous modulus of the black tea powder suspension. Moreover, black tea powder with small particle size could regulate blood lipids in a hyperlipidaemic rat model by lowering triacylglycerols and elevating high-density lipoprotein cholesterol, whereas large particles presented an advantage in reducing body weight. CONCLUSION Our investigation extended the knowledge of commercial black tea powder in composition, physical, rheological, and bioactive properties. These results lay the foundation for future exploration of the use of tea powder in the food industry. (c) 2022 Society of Chemical Industry