Abstract The present study aims at optimizing the cyclone performance for a fixed total cyclone height. The objectives include reducing both pressure drop and cut-off diameter. Response surface methodology (RSM) based on the desirability approach is used to optimize the cyclone performance. Table of runs is constructed using Box-Behnken design method for five independent variables viz. vortex finder diameter and its insertion length, cylinder diameter and its height, and cone tip diameter of cyclone. Muschelknautz method (MM) of modeling is used to predict the values of dependent variables to fill the spread-sheet. The cyclone model with a new set of optimized geometrical values is analysed using numerical simulations and comparison of the results against the standard model shows significant improvement in the cyclone performance.