In an industrial gas-phase polyethylene reactor, the safe operating range of temperature is rather narrow. Even within this temperature range, temperature excursions must be avoided because they can result in low catalyst productivity and significant changes in product properties. If the manipulated variable for temperature control saturates (i.e., the cooling water valve position is completely open), then the reactor operates without a feedback temperature controller, leading to oscillatory behavior and limit cycles. In this work, it has been demonstrated that the saturation in the manipulated variable and the complex non-linear dynamic behavior are removed when auxiliary manipulated variables, obtained by bifurcation analysis, are used in a multivariable control strategy for the reactor temperature control. Two control structures are proposed and compared considering their impact in the reactor production and polymer melt index. In the first control structure, the designed PID controller for the reactor temperature is considered and a switching strategy with a PI controller for the auxiliary manipulated variables is included. In the second control structure, the designed PID controller for the reactor temperature is also used, however, a MPC controller for the auxiliary manipulated variables is considered. The results suggest that the use of gain-scheduling strategy in the PID temperature controller with a MPC controller for the auxiliary manipulated variables avoids the saturation of the manipulated variable and, hence, the undesired nonlinear dynamic behavior, reducing the production loss and improving the product quality. (C) 2008 Elsevier Ltd. All rights reserved.