Particle size and morphology are of high industrial importance due to the fact that product properties and performance can be affected by this factors. For instance, bulk properties, processability and appearance of the final product are given by particle size and shape. In this regard, the optimization of process parameters for particle development is required when targeting formulation of specific product and/or particular properties. Response surface methodology (RSM) was used to optimize the spray drying process for the development of aquasolv lignin particles with desired particle size and morphology. The inlet drying temperature X-1: 180-200 degrees C, atomization pressure X-2: 1.3-1.7 bar and feeding rate X-3: 65-75 mL min(-1) were kept as independent variables while the optimizing responses were: Yield fine of particles with desired particle size and particle size (D-50). The quadratic part of the equation and statistical analysis showed substantial effect of the atomizing pressure and feeding rate on the responses and the optimized conditions validated the model. Optimum processing conditions for spray drying of aquasolv lignin were inlet temperature of 173 degrees C, 1.8 bar atomization pressure and 62 mL/min feeding rate. With this, desired responses of powder were 66% of yield and particle size of D-50 < 30 mu m were obtained. The experimental values were found to be in agreement with the predicted values indicating the suitability of the model in predicting the particle size and yield of aquasolv lignin. (C) 2020 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.