This work investigates catalyst shaping in top spray fluidized beds and its impact on properties at different levels: particle growth stages, zeolite dispersion within the catalyst particles, and their combined effects on active site accessibility and activity in methanol to hydrocarbons (MTH) reaction. We examine the influence of process parameters such as viscosity, atomization, fluidization, temperature, slurry flow, and initial bed mass on particle size distribution and morphology. Dimensionless number analysis clarifies the dominant growth stage for a given set of process parameters. We elaborate more on optimizing the conditions that maximize zeolite, linked to smaller zeolite size, faster diffusion of probes such as 2, 2-dimethylbutane, and slightly higher activity (without violating the reaction mechanism). By optimizing the dispersion of zeolite through catalyst shaping conditions, we achieved 100 % zeolite utilization, compared to 70 % under non-optimized conditions. This improvement would have a significant impact on scaling this shaping technology.