BACKGROUND: This paper presents a mathematical modeling and factorial analysis of the toluene combustion activity of a cordierite monolith supported copper-manganese-silver mixed-oxide catalyst in the drying and calcination processes, using response surface methodology. A central composite rotatable design is performed to collectively study the effect of drying temperature, calcination temperature and calcination time. Experimental results are provided to confirm the validity of the models developed. RESULTS: The calcination temperature is the most significant process factor affecting the catalytic combustion activity. It is also shown that the combustion activity increases in most cases with decreasing calcination time and that a moderate calcination or drying temperature is required to increase the combustion activity. The optimal factor levels are drying temperature 160 degrees C, calcination temperature 500 degrees C, and calcination time 3 h. CONCLUSIONS: There is significant scope to improve the combustion activity of the monolithic catalyst through the optimization of the drying and calcination process factors. Response surface methodology is an effective technique for mathematical modeling and factorial analysis of the catalytic activity of monolithic catalysts. (C) 2010 Society of Chemical Industry