A systematic study of the terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate (BA/MMA/VAc) was conducted. Complete replication of an emulsion terpolymerization experimental nln was performed in a 5-L stainless-steel batch pilot-plant reactor The polymers produced were characterized for conversion, terpolymer composition, molecular weight averages and average particle size. A hierarchical (nested) data analysis was performed on the experimental data to ascertain various sources of error and to allow for comments to be made regarding the data quality.