Abstract: A process for immobilizing viable cells in gelled carrageenan beads comprises preparing an aqueous phase that is a mixture of a gellable concentration of un-gelled carrageenan, in an aqueous suspension of viable cells, in which the mixture's potassium concentration is low enough that the thermogellation temperature of the carrageenan in the suspension is below a temperature to which the viable cells are substantially thermosensitive. This is done at a first processing temperature that exceeds the thermogellation temperature of the carrageenan in that aqueous suspension, but which is below the temperature to which the cells are substantially thermosensitive. A mixture of the aqueous phase and a non-reactive food-grade oil phase is then prepared, and subjected to shear by passing it through a static mixer under flow-rate conditions selected to disperse the aqueous phase in the oil phase, such that a resulting emulsion has a selected droplet size distribution.