There is provided a method of producing microparticles using an emulsion based synthesis route including: Providing a first fluid phase and a second fluid phase, wherein the first fluid phase is a continuous phase and the second fluid phase is a dispersed phase comprising a dispersed material, wherein the continuous phase is immiscible with the dispersed phase; Mixing the first continuous phase and the second dispersed phase in the presence of a surfactant in a shear device to form an emulsion of droplets of controllable size and having a narrow drop size distribution; Drying the emulsion to form microparticles of controllable size and having narrow size distribution, and wherein the microparticles may comprise spherical, crumpled, dimpled, porous or hollow microparticles morphology. Also provided is a system including shear device and drying arrangement. Also provided are micro particles of controllable size and morphology formed by the method.