Encapsulate beads composed of alginate and chitosan as shell and bovine serum albumin (BSA) as core were prepared by combined method of complex coacervation and electrospray. The main objective of this work was to produce mono-sized and spherical capsule of chitosan-alginate with controlled sizes of capsules and shell. However, the effects of applied voltage, flow rate, and molecular weight of chitosan were investigated on the size, size distribution, membrane thickness of the prepared capsules, as well as the release rate of BSA. The results revealed that by the method developed in this study, it was possible to produce spherical capsules with controlled size and narrow size distribution. Increasing the voltage and decreasing the flow rate reduced the radius of capsule and its shell thickness from 2.09 mm to 750 mu m and from 1.31 mm to 490 mu m, respectively. Furthermore, the molecular weight of chitosan had no significant effect on the capsules' size and the release rate of BSA, whereas the rate of BSA release was increased with increase of the voltage. The later effect would be due to the increase of shell porosity at the higher voltages. (C) 2010 Wiley Periodicals, Inc. J Appl Polym Sci 117: 322-328, 2010