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During the casting of the propellant slurry in the case (around the mandrel), there is local variation in the distribution of the oxidiser particles due to the shear induced migration in the highly viscous flow. This leads to the heterogeneity in the propellant grain composition, responsible for nonuniform burn rates (midweb anomaly). The flow behavior of the slurry is complex due to the high solid content, non?Newtonian rheological profile and grain geometrical features. The transport of the solids due to the local fluid flow pattern during the casting process, determines the anomalies in the grain microstructure and composition. Since a lot of factors and complexities are involved in the casting process, a complete numerical investigation based on the CFD technique is being carried out. The project envisages the optimization of process conditions and geometric configurations to minimize the web anomalies in the propellant grain, towards achieving uniform burn rate.