A holistic assessment to appreciate and validate the effects of process variables in gas atomization of eutectic aluminum-silicon alloy, has been carried out by mean of a mathematical algorithm and an experimental design. In this, each one of process stages was simulated applying their principles. Variables analyzed were molten alloy superheat and both volumetric flow rate and pressure in gas pipeline, while the property evaluated was the mean particle size. Both mathematical and physical models were employed to generate the mathematical relationships, which were necessary to build the simulation program. Simulation software was elaborated using TURBO PASCAL 7. 0. Experimental design was carried out conform to molten alloy and gas supply equipment capacity, and measure and control instruments capacity. Samples of 200 grams of alloy were atomized and screened for size particle distribution. Both calculated and experimental dates for mean particles size were compared. Good agreement was obtained; this validates the holistic algorithm.