Styrenelbutyl acrylate batch miniemulsion copolymerizations were performed in a 1.2 L stainless steel reactor. Conversions were monitored off-line using gravimetry and in-line using ATR-FTIR spectroscopy. The final latexes were coated on a polyethylene terephthalate carrier and dried at room temperature for 2 days. Their performance as pressure-sensitive adhesives (PSAs) was evaluated by measuring their tackiness, peel strength and shear strength. By using a constrained mixture design, the influence of particle size and copolymer composition was investigated. Particle size was found to be the most influential factor for both tack and peel strength models. Tack showed a concave upward trend whereas peel strength decreased with increasing particle size. Shear strength decreased with increasing particle size but was also significantly influenced by copolymer composition. The final forms of the models allowed 3D response surfaces to be built and an optimal adhesive performance region (highest combined tack, peel strength and shear strength) was located near the smallest particle diameter investigated with the highest styrene composition. The positive effect of smaller particles on every adhesive property relates to the tighter packing provided by smaller particles during the drying process, thus increasing the area of contact between the adhesive and the substrate. (c) 2005 Elsevier Ltd. All rights reserved.