AbstractAn interesting feature of commercial continuous emulsion polymerization reactors is the important phenomenon of sustained oscillations. Laboratory investigations of emulsion polymerization in a continuous stirred tank reactor (CSTR) have shown that the conversion, number of polymer particles and other related properties often oscillate widely with time. These oscillations can lead to emulsifier levels too small to adequately cover polymer particles resulting in excessive agglomeration and reactor fouling. Herein is reported an extensive experimental study of vinyl acetate emulsion polymerization in a CSTR. The effects of initiator and emulsifier concentrations, mean residence time and rate of agitation on the production rate and size distribution of polyvinyl acetate latices were investigated. Domains of reactor operation which give rise to sustained oscillations and massive agglomeration of the latex are mapped which give rise to sustained oscillations and massive agglomeration of the latex are mapped out. The effect of different start‐up policies on reactor transients were also investigate