Summary Varying material particle sizes represent a common contributing factor to the batch‐to‐batch variation of extraction yields. To increase the batch‐to‐batch quality consistency of extracts, a method was proposed to adjust the extraction conditions for different material particle sizes, taking the hydrodistillation extraction process of Radix Curcumae and Fructus Gardeniae as a case study. Statistical models were built for five sesquiterpenes including curcumenone, curcumenol, curdione, curzerenone and furanodienone, to quantitatively describe the effects of particle size and process parameters on their extraction yields. An increase in sodium chloride concentration remarkably increased the yields of curcumenone and curcumenol, and a larger solvent‐to‐solid ratio increased the yields of five sesquiterpenes. Under the adjusted process parameters for two different particle sizes, the yield for each compound was controlled to fall in the 90–110% target range. The proposed method can be applied to various extraction processes of foods and herbal medicines.