The coarse, Fe-containing intermetallic particles which form during ingot casting are well known to play important roles in determining the downstream microstructural development and final gauge properties of rolled aluminium alloy products. To understand, and ultimately to predict and control these various influences, it is necessary to know how the intermetallic population itself develops through the process stream. The phase type, morphology, and size and spatial distribution of the constituent particles in a final gauge sheet or foil product will be the result of the complete sequence of manufacturing steps which have been applied, from ingot casting through to cold rolling. This paper describes work conducted to improve understanding of the development of the coarse particle population through these various processing stages. Drawing upon examples from several different alloy systems and end applications, it illustrates how a greater appreciation of the mechanisms involved is leading to a better capability to predict this important aspect of microstructural evolution in wrought aluminium alloys.