This study investigated the effects of atomization at low air-to-liquid mass flow rate ratios (m)over dot(air)/(m)over dot(liq) on the size, size distribution and shape of the calcium alginate (Ca-alginate) particles produced. It was found that the (m)over dot(air)/(m)over dot(liq) ratio must be greater than 0.0011 to atomize a 20 g/L sodium alginate solution. Ca-alginate particles with a broad mean sizes ranging from 50 to 2300 mu m were produced using a (m)over dot(air)/(m)over dot(liq) ratio lower than 3.5. The change in particle size was most significant when the (m)over dot(air)/(m)over dot(liq) ratio was below a critical value 0.25. An increase in the (m)over dot(air)/(m)over dot(liq) ratio decreased the mean particle size but increased the particle size distribution. The particles became more spherical with an increase in the (m)over dot(air)/(m)over dot(liq) ratio. (C) 2011 Elsevier Ltd. All rights reserved.