This work concerns robust controller synthesis using the differential geometric concepts for minimum phase nonlinear systems with immeasurable disturbances. A pseudo-linearization of the disturbance model at the input-output linearization stage is applied to yield a linear subsystem for controller design. Based on this linear model, a multi-loop controller framework is implemented, whereby mu-synthesis is used to design off-line robust controller in the outer loop while state feedback is implemented in the inner loop. Through proper selection of weights, the outer robust controller is explicitly designed to address both uncertainty and disturbance rejection whereas the inner controller is used for on-line static state feedback. Numerical simulations are used to illustrate robustness of the controller for multi-input multi-output temperature control in two non-isothermal continuous stirred tank reactors in series. (C) 2003 Elsevier Ltd.