Diclofenac wax microspheres were prepared using the congealable disperse-phase encapsulation method. Emulsifiers, glyceryl monostearate (GMS) and stearic acid, were added to improve the efficiency of emulsification. Microspheres containing either of the emulsifiers or both showed a high drug content (80-90%) and the particle size distribution was log-normal compared with microspheres without the emulsifiers. Increase in GMS concentration decreased the drug release and, in contrast, stearic acid appeared to channel the drug from the wax matrix. The addition of both emulsifiers at different concentrations modified drug release. Increase in dispersant (PVP) concentration, and decrease in microsphere size accelerated the rate of drug release. Higuchi/Baker Londsdale spherical matrix dissolution kinetics was followed. Disintegrating tableted microspheres were prepared with Avicel(R) and Explotab(R). With the increase in compression pressure the crushing force and disintegrating time increased, but the thickness decreased, and the dissolution profile did not appear to be affected. Slightly faster release was noticed with tableted microspheres compared with that of uncompressed microspheres. Tablets containing 40 and 60% microsphere loadings had disintegration times of 5.12 +/- 0.63 and 57.73 +/- 3.53 min, respectively. In contrast, tablet formulation containing 80% microsphere load had a significant, increase in disintegration time (130.83 +/- 4.26 min). The dissolution from this formulation also showed a lag time of 30 min in contrast with the other two formulations, which showed no lag time. Increased microsphere size from 215 to 630 mum had no effect on tableting properties (such as hardness and thickness); and only very little effect on dissolution. The microspheres appeared deformed but intact irrespective of compression pressures on scanning electron micrographs.