A new approach in the formulation of hydrogel beads by emulsification/in situ thermal gelation using static mixer technology is described. K-Carrageenan was selected as the model hydrogel. The emulsion generated by a Sulzer SMX6 static mixer consisted of warm K-carrageenan so] (1.5% w/w in water or 10 mM CaCl2) as the dispersed phase, and ambient temperature sunflower seed oil as the continuous phase. Dispersion followed by in situ gelation Of K-carrageenan droplets was possible within a short residence time (1-2 s) in the static mixer, under defined operational conditions, known as the feasibility region. This region was defined as the zone of operation conditions necessary to obtain discrete gel beads, within a defined range Of K-carrageenan solution injection temperature, volume fraction and total flowrate. The temperature boundaries of the feasibility region were determined by the K-carrageenan gelation temperature and solution viscosity. The resulting beads had a Sauter mean diameter ranging from 350 to 200 Inn, which decreased with the increase of K-carrageenan injection temperature, total flowrate and/or the number of static mixer elements. Theoretical values of maximal bead diameter and Sauter mean diameter were calculated on the base of critical Weber number, which was demonstrated through good agreement with the experimental values. It was demonstrated that an existing model for the prediction of gel bead diameter in a SMX static mixer is applicable for the new procedure described in this study. (C) 2004 Elsevier Ltd. All rights reserved.