The present invention provides a process for making a solid antiperspirant stick comprising a particulate aluminum antiperspirant salt suspended in an anhydrous carrier vehicle, wherein said carrier vehicle comprises a high melting component which melts at 70.degree. C. or higher. This process includes heating the carrier vehicle in a closed mixing vessel to a temperature in excess of 70.degree. C. preferably in excess of 75.degree. C., to melt the high melting component, adding the antiperspirant salt to the carrier vehicle, and cooling the carrier vehicle to form a solid antiperspirant stick. The improvement of the present invention comprises cooling the carrier vehicle below 70.degree. C., preferably to about 65.degree. C. or less, but above the solidification point prior to adding the antiperspirant salt and maintaining the carrier vehicle below 70.degree. C., preferably at about 65.degree. C. or less, during and after the antiperspirant salt addition, thereby substantially preventing agglomeration of the antiperspirant salt into large particles, especially particles in excess of 60 microns.