The effect of processing conditions on the mean size, size distributions and mechanical properties of porous agarose beads manufactured by an emulsification methodology conducted in a single stirred vessel has been investigated. It has been found that the relation between particle size and average energy dissipation rate is similar to one developed for turbulent flow and that the mechanical properties of the beads depend on hydrodynamic conditions at formation and the load applied to the beads. The results imply that manufacturing of porous beads in a stirred vessel is an attractive alternative to the emulsification carried out in high shear emulsifiers. (c) 2005 Elsevier B.V. All rights reserved.