The objective of this study is to prepare, evaluate, and understand carrageenan gelation. By using these properties of κ‐carrageenan, beads are created by thermal gelation. A warm κ‐carrageenan solution is extruded dropwise into a cold air column; the particles are collected. The relationship is studied between the process variables on the shape and size of κ‐carrageenan drops after gelation is established with the aid of image analysis. Thanks to these measurements, a model is developed to present satisfactory performance in industrial application. Mathematical models for κ‐carrageenan prilling, its simulated results, the parameters of equipment for the innovated process, and its application are addressed.