Effect of various atomization methods and solute concentration on the morphology of spray dried magnesium sulphate particles is investigated. Four types of atomizers are characterized and tested including (i) a vibrating mesh nebulizer, (ii) a splash plate nozzle, (iii) an air mist atomizer, and (iv) a pressure atomizer. Several types of particle morphologies are identified in this research. Spray characteristics, such as droplet number density, droplet size, and velocity, and accompanying atomizing air have major influence on the drying and morphology of the particles. High initial solute concentrations result in the formation of thick-walled particles, and this prevents the particles to burst. It is found to be difficult to obtain fully filled magnesium sulphate particles, even for saturated solutions at room temperature because the solution equilibrium saturation changes substantially with temperature.
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