The size and stability of latex particles in the semibatch emulsion polymerization of butyl methacrylate (BMA), in the presence of 0-10% methacrylic acid (MAA), were investigated. Response surface methodology (RSM), as a design of experiment, was used to obtain a more systematic understanding of the role of emulsifier and MAA in the stability of the particles. The amount of coagulum can be greatly reduced by increasing the concentration of sodium lauryl sulfate (SLS) in the monomer emulsion feed (MEF) and initial reactor charge (IRC). On the other hand, increasing the concentration of SLS in the IRC can result in a decrease of the particles size. According to the experimental data, the yield of reaction can be improved with incorporation of MAA into the emulsion polymers. The size and morphology of particles were obtained by scanning electron microscopy (SEM). FTIR and titration were used to determine the percentage of MAA in the copolymer. (C) 2007 Wiley Periodicals, Inc.