In this work, a new control strategy for controlling the particle size distribution (PSD) in emulsion polymerization has been proposed. It is shown that the desired PSD can be achieved by controlling the free surfactant concentration which in turn can be done by manipulating the surfactant feed rate. Simulation results show that the closed-loop control of free surfactant concentration results in a better control of PSD compared to open-loop control strategy, in presence of model mismatch and disturbances. Since the on-line measuring of ionic free surfactant concentration is difficult, conductivity which is related to it is measured instead and used for control purposes. The closed-loop control of conductivity also results in a better control of PSD compared to open-loop control strategy, but its performance is not as good as controlling free surfactant concentration in presence of model mismatch. (c) 2008 Elsevier Ltd. All rights reserved.