Macro-Batch and Continuously Operated Microfluidic Emulsification—Differences, Similarities and Optimization

Abstract

In this work, the emulsification of oil-in-water two-phase systems with three emulsifiers (PEG1500, 6000 and 20000) was studied in a batch macro system and in a continuously operated microfluidic system. The effect of emulsifier concentration, oil concentration and mixing rate on zeta potential and average Feret diameter was analyzed for the macro-batch system, while the effect of emulsifier concentration, oil concentration and total flow rate on zeta potential and average Feret diameter was analyzed for the microfluidic system. The emulsions prepared in batch system were more stable, had smaller droplet diameter but higher values of polydispersity index (PDI) compared to those prepared by continuous method. In both cases, batch and continuous, the use of PEG with higher molecular weight resulted in emulsions with lower zeta potential values. In batch emulsification, all three optimization parameters (emulsifier concentration, oil concentration and mixing rate) had a significant influence on the average Feret diameter and zeta potential (depending on the PEG, used for emulsification), while the emulsifier concentration had the most significant influence on the zeta potential and average Feret diameter of emulsions prepared in the continuous microsystem process.