The effect of formulation (filler’s kind and amount, liquid’s kind and concentration required for granulation) and spheronization time on characterization of alumina based pellets parameters (pellets size distribution, roundness and aspect ratio) were investigated. Two schemes were successfully proofed by extrusion/spheronization. The mean volume particle diameter was found to have a profound effect on the formulation and processing parameters. Alumina powder with large mean volume particle diameter showed different mechanism of action with coupling agent. With the surface modification, the water required for granulation had decreased. The existing formal and kinematic velocity of the water had a direct effect on the processing parameter of the extrusion and spheronization. Spheronization time from 2 to 10 min had a pronounced effect on roundness and aspect ratio. No changes in roundness and aspect ratio were observed from 10 to 20 min of spheronization time.