The effect of low air-to-liquid mass flow rate ratios on the size, size distribution and shape of calcium alginate particles produced using the atomization method

► Alginate solution was atomized using m˙air/m˙liq lower than 3.5. ► Ca-alginate particles with mean sizes ranging from 50 to 2300 μm were produced. ► Increase in m˙air/m˙liq decreased mean particle size but increased size distribution. ► Particles became more spherical with an increase in m˙air/m˙liq. ► The process is easy to set up, economical and scalable.