This paper examines the effect of mixer size on the density of the propellant and it also explores the role of the propellant density with regards to burning rate and burn rate pressure index. Propellant samples were prepared in the four different size (15, 70, 200 and 1000 g) mixers with identical input of ingredients to examine the effect of mixer size on density and burning rate of the composite solid propellant. It was noticed that density and burning rate of the propellant changes significantly with change in the mixer size from 15 g to 1000 g. This is because for the smaller mixers the surface area to volume ratio is large and the actual percentage of aluminum and ammonium perchlorate (especially coarse) that goes into the propellant reduces. High burning rate with decrease in mixer size is also accompanied with increase in burn rate pressure index. The composition analysis was also carried out and it is noticed that the actual percentage of the ingredients is different from the intended percentage of the ingredients and percentage change is more when the mixer size decreases. © 2013 IAA.