This paper investigated the effects of heat treatment (75 °C × 18 s and 100 °C × 18 s) and wet-mix total solids level (TS: 50 and 60%, w/w) on the physicochemical and techno-functional properties of model infant milk formula (IMF) powders. IMF produced from wet-mixes with 50% TS preheated at 75 °C (50%-75°C) exhibited the longest wettability time (55 ± 2 s) and the poorest flowability, explained by the small particle size (D [4;3]= 16.5 ± 2.29 μm) and low poured bulk density (0.27 ± 0.02 g/cm3). Larger particles were obtained by increasing both pasteurization temperature and TS. Further, powders from 60% TS wet-mixes showed less particle size uniformity, leading to better packing and higher bulk densities. 50%-75°C powders also showed the lowest onset glass transition temperature, which may affect its storage stability. Wettability time was reduced by increasing TS from 50 to 60% or by increasing pre-heating temperature from 75 to 100 °C. However, as observed by low-field nuclear magnetic resonance, the increase in the pasteurization temperature slowed down the global rehydration process. The flowing properties of the powders improved by increasing TS level of the wet-mix. In conclusion, the pre-spray drying wet-mix processing variables, pasteurization temperature and TS level, had a major effect on the physicochemical and functional properties of the IMF powders. It is crucial to understand how variations in the process parameters affect these powder characteristics, due to their functional, technological and economic importance.