Abstract Milling and air classification settings were optimised for production of protein concentrates from Australian faba bean, yellow pea and red lentil seed material. Pulses were milled to flour of three progressively finer particle size distributions (D50 of 23–25, 16–18 and 13–14 μm) and air classified at classifier wheel speeds of 7080, 9600 and 10,200 rpm. Maximum protein concentration was reported for pulse flours (D50 of 13–14 μm) at 9600 rpm. Protein concentrations of 61.4, 58.1 and 61.0 g/100 g (db.), reflecting a fold increase in protein content of 1.9, 2.3 and 2.1, were reported for faba bean, yellow pea and red lentil, respectively. Protein, ash, fat and total dietary fibre contents were significantly higher in fine fractions (p