Shaping and optimal compositional formulation are major challenges in the successful industrial application of heterogeneous catalysts. The choice of components during formulation plays a vital role in endowing the final catalyst’s mechanical strength, durability, lifetime and may even affect activity and selectivity. Herein, we evaluate the application of spray-drying to manufacture spherical ZSM-5 based catalysts and their applicability in the methanol-to-olefins (MTO) process. Several critical parameters of the spray drying process and various aspects related to catalyst formulation (binder, zeolite, clay) are investigated. Chemical composition and structure of the clay matrix substantially influence the catalytic performance.