Controlling liquid distribution in a wet granulation process is critical to maintaining control of both nucleation and growth, as highly-saturated patches created by uneven liquid distribution will have a much higher growth rate and may form large “balls”, commonly 2-3cm diameter or larger. This paper presents a case study of attempting to improve the liquid distribution during manufacturing of an existing wet-granulated product with a long history of “balls”. The flowrate and spray area of the original nozzle were measured, and a simple estimation of the drop size was obtained by a high-speed photograph and image analysis. The powder surface velocity in a 400L Diosna was measured using a high speed camera and a simple image analysis technique for several batches using different lots of the drug. A new nozzle was selected and implemented in a full-scale production batch and the results are compared with the original nozzle conditions. Reducing spray flux by changing the nozzle actually increased ball formation, contrary to what was expected. Increasing the efficiency of liquid distribution may mean that less total liquid is required to be added to achieve the same extent of granulation. The study found that the major contribution to batch-to-batch variation in spray flux was the large variations in powder surface velocity for each batch, presumably due to changes in the physical properties of each lot of drug. This has important implications for understanding the causes of variability in liquid distribution and granule/ball size in full-scale production of wet granulated pharmaceutical products.