A method includes spraying a liquid including polymer and a gas substantially inert to the liquid respectively from a first and second orifice of a nozzle into air to form mist of beads. The beads then are collected with a collecting medium at a temperature in a range from about 10 C. to about 80 C. The collecting medium includes at least one of water and alcohols.

A method for forming spheroidal particles including inducing flow of a slurry of particles and a reactant through one or more orifices, detaching an amount of the slurry from the slurry flow following exit from the one or more orifices, the detached amount forming a slurry body, forming the slurry body into a spheroidal shape, contacting the spheroidally shaped slurry body with a coagulation solution to form a stabilized spheroidal particle and drying and/or sintering the stabilized spheroidal particle.

A method of making solid beads is disclosed, said method comprising: (i) providing a microfluidic device comprising a carrier fluid conduit and a functional fluid conduit which meet at a junction region; (ii) providing a laminar flow of a functional fluid comprising a solvent and a solute along the functional fluid conduit and providing a laminar flow of a carrier fluid along the carrier fluid conduit so as to form droplets of functional fluid in a flow of carrier fluid; (iii) cooling the segments of functional fluid in a conduit of the microfluidic device to form cooled (preferably frozen) droplets; and (iv) providing a liquid into intimate admixture with the cooled droplets so as to cause said solvent to exit said cooled droplets, thus forming solid beads. A microfluidic device for use in such a method is also disclosed.

A method of making solid beads is disclosed, said method comprising: (i) providing a microfluidic device comprising a carrier fluid conduit and a functional fluid conduit which meet at a junction region; (ii) providing a laminar flow of a functional fluid comprising a solvent and a solute along the functional fluid conduit and providing a laminar flow of a carrier fluid along the carrier fluid conduit so as to form droplets of functional fluid in a flow of carrier fluid; (iii) cooling the segments of functional fluid in a conduit of the microfluidic device to form cooled (preferably frozen) droplets; and (iv) providing a liquid into intimate admixture with the cooled droplets so as to cause said solvent to exit said cooled droplets, thus forming solid beads. A microfluidic device for use in such a method is also disclosed.

A method of creating hydrocolloid beads includes forcing a hydrocolloid gel suspension through a plurality of nozzles, wherefrom the hydrocolloid gel forms into a plurality of gel drops and fall into a reactant bath. The drops are exposed to the reactant bath for a predetermined period of time, wherein the drops form firm or semi-firm beads as they remain in the reactant bath. The firm or semi-firm beads are removed from the reactant bath, rinsed, and dried.

A method of creating hydrocolloid beads includes forcing a hydrocolloid gel suspension through a plurality of nozzles, wherefrom the hydrocolloid gel forms into a plurality of gel drops and fall into a reactant bath. The drops are exposed to the reactant bath for a predetermined period of time, wherein the drops form firm or semi-firm beads as they remain in the reactant bath. The firm or semi-firm beads are removed from the reactant bath, rinsed, and dried.