A systematic study of the terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate (BA/MMA/VAc) is being conducted. In this stage of the study, emulsion terpolymerizations were performed in a 5 L stainless steel pilot plant reactor. The experimental trials were of the two-level factorial type and were designed optimally using a Bayesian method. The design procedure allowed us to improve our knowledge about the process using our prior knowledge and our subjective judgement. The polymers produced were characterized for conversion, composition, molecular weight, and particle size. The Bayesian design of experiments is shown to have several advantages over conventional factorial designs.