How does creating an irreducible representation for an adaptive design search space affect search efficiency for small search budgets and a high-variance particle packing objective function? Solid rocket fuel propellants consist of several different types of particles (i.e. a formulation), where the size mean and standard deviation generally follow a log-normal distribution and are controlled by milling parameters and milling time, respectively. In particular, longer milling times tend towards lower standard deviations. High packing fractions are important when increased stability of solid rocket fuels is desired. Physics-based simulations are often used prior to experimental synthesis due to the energetic nature of the formulation constituents (in particular, ammonium perchlorate), made soberingly apparent in the PEPCON disaster in 1988, a chemical explosion that caused two fatalities, hundreds of injuries, and ∼$100 million worth of damage .