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ZnO nanostructured thin films were grown by spray pyrolysis on alumina substrate pre-patterned with gold interdigitated electrodes at three different substrate temperatures (viz 350°C, 400°C and 450°C). Crystal structure and morphology were determined by GIXRD and FESEM respectively. Ammonia sensing experiments were then performed in the in-house designed Exposure Facility for Gas Sensing (EFGS) at different operating temperatures. The effect of minute changes in morphology on gas sensing was studied and optimum synthesis and operating temperatures was arrived at and related towards efforts to synthesize an efficient ZnO based thin film sensor.