The present investigation was aimed to observe the effect of particle size on physical, sensory and thermal properties of foam-mat dried mango pulp powder. Mango pulp of Dussehri variety was foam-mat dried using 3% egg white at 65C. Dried foam-mats were pulverized and passed through a sieve shaker for obtaining three grades of powder with 50, 60, and 85 mesh size sieves. The particle size of these samples measured using laser diffraction particle size analyzer ranged from 191.26 to 296.19 μm. The data was analysed statistically using ANOVA of SAS. There was a linear increase in lightness (‘L’ value) with a decrease in particle size, however, ‘a’ value decreased with a decrease in particle size, indicating the decrease in redness. An increase in bulk density and decrease in water solubility index and water absorption index % were observed with a decrease in particle size. Particle size had a significant effect on sensory parameters. Particle size in the range of 258.01 to 264.60μmwas found most acceptable with respect to sensory characteristics. This finding can be exploited for various commercial applicationswhere powder quality is dependent on the particle size and has foremost priority for end users.