An overall comprehensive modeling and simulation experimental design with conical hoppers were done. Results showed high correlation among measured dependent variables. A comprehensive regression model for mass flow rate as a function of Hausner ratio and Angle of Repose was developed, which provided predicted optimum ranges of Hausner ratio and Angle of Repose for “good,” “fair,” and “poor” flow. Based on this result, predicted optimum ranges of moisture content for “good,” “fair,” and “poor” flow was determined. Drying temperature, cooling type, and consolidation temperature were most significant variables in predicting mass flow rate from hopper. Johanson model (theoretical model) was calibrated and modified for predicting mass flow rate as a function of packed bulk density, for conical hoppers.