The objective of this study is to prepare, evaluate, and understand carrageenan gelation. By using these properties of kappa-carrageenan, beads are created by thermal gelation. A warm kappa-carrageenan solution is extruded dropwise into a cold air column; the particles are collected. The relationship is studied between the process variables on the shape and size of kappa-carrageenan drops after gelation is established with the aid of image analysis. Thanks to these measurements, a model is developed to present satisfactory performance in industrial application. Mathematical models for kappa-carrageenan prilling, its simulated results, the parameters of equipment for the innovated process, and its application are addressed.