A brief introduction into catalyst shaping and its importance is given. Some challenges and key aspects are discussed. A special attention is paid to visualization of the structure of catalyst extrudates. Hydrous sulfated zirconia, as a promising catalyst for acid catalyzed transformations of hydrocarbons such as alkylation, is considered from the viewpoint of its shaping via extrusion. Rheology and zeta potential measurements are presented for this material, addressing also the influence of PVA addition as a surface-modifying agent. The quality of the green bodies of the shaped catalysts is shown to be strongly dependent on particles surface properties in molding masses.