Spray drying has been used in the production of fine powders from emulsions for many years, but it is not a process in which most people associate the production of microspheres.? This journal article shows how the authors were able to produce highly spherical microspheres in the 2-10um range by controlling the levels of Chitosan and crosslinking agents used.
The key items I found of interest in this article were:
The quality of the microspheres that were produced, as seen the the attached SEM micrograph.
How the process variables did not affect the zeta potential of the microspheres produced (Table 4 below), and how the size can be varied by varying the concentrations of Chitosan or the Molecular weight (MW).
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