The combined influences of KOH initial concentration and initial lead precursor excess on the characteristics (morphology, powder density, specific surface area, crystalline structure and powder chemical composition) and sintering behaviour of hydrothermally synthesised powders, have been investigated. Optimised conditions (low KOH concentration and presence of lead excess in the feedstock) have been determined that lend to fine deagglomerated and reactive PZT powders densifying at about 850 degrees C. A Pb-rich surface layer has been identified over the grains, that is responsible for this low sintering temperature. Despite the large excess of lead, the cole of powders remains lead deficient. But by lowering [KOH](o), it is possible to keep the lead deficiency within a few percent. (C) 1999 Elsevier Science Limited. All rights reserved.