Emulsification

Emulsification is the process of dispersing one liquid in a second immiscible liquid. For example, mixing oil into water - we see this first-hand in the everyday kitchen process of combining oil, egg yolks and vinegar to make a thick creamy mayonnaise. 

Successful mixing can be achieved by mechanical means, such as using a mechanical blender like a kitchen mixer (a homogeniser), shaking or by microfluidic mixing where droplets of one substance are dispersed inside the second substance. If no emulsifier has been added (in the case of home-made mayonnaise this is what the egg yolk does), then the two phases will rapidly separate back into two distinct layers. So, the stability and quality of an emulsion is an interaction between the two phase raw material properties, emulsion ratios, choice and concentration of emulsifier and how the two phases have been blended together.
Narrow particle size distribution = stability
A very broad emulsion droplet size distribution can result in droplets with different buoyancies, potentially causing creaming and sedimentation, which require a greater concentration of emulsifier to stabilise.

In the images above, it is easy to see the difference in particle size distribution our equipment offers compared to conventional 'brute force' homogenisation.  The tighter droplet size control provides a much more stable emulsion and improved final product. ​
Micropore's technology produces superior emulsions even for formulations using high viscosity ingredients, delivering highly reliable and reproducible emulsions. Whether through batch or continuous processing routes.

Micropore membrane emulsification
Our membrane emulsification technology introduces the two phases together in a carefully controlled manner. By injecting the ‘dispersed phase’ through the pores of a precision engineered, laser drilled, stainless steel membrane, this forms a spherical droplet as it emerges from the pore, into the ‘continuous phase’. 

By applying controlled shear at this point the droplet deforms and detaches from the membranes surface, giving a consistent and controllable droplet of a pre-determined size. ​Now imagine this happening across the surface of the whole membrane. Reliability and reproducibility mean that there are no 'bad batches', so waste is minimised.  ​​

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​Benefits of Micropore's hygienic stainless steel equipment 

• Suitability for pharmaceutical, food, cosmetics and other industries requiring sterile environments.
• Can run at highly elevated temperatures.
• Reduced footprint versus traditional equipment.
• Scalability from laboratory formulation testing, through to production tonnages.

Solving formulation challenges
​At Micropore we work in partnership with our clients to overcome formulation challenges including the development of more environmentally desirable formulations: e.g. replacing or reducing the need for emulsifying agents such as polyglycerol polyricinoleate (PGPR), where Micropore's process delivers the lower shear, greater stability and control required.

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Applications

Pharmaceuticals

Food and Beverages

Cosmetics, Fragrances and Skincare

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​​Working with Micropore was a very positive experience for us.
​The speed with which we progressed reflects how user-friendly we found the Micropore equipment.

​Customer, food sector

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​We have achieved significantly improved production economics. We were initially sceptical as we had had problems when we’d tried membrane emulsification in the past.  Micropore has developed a truly elegant solution

Customer, ​household products

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​​We set aside a day for trials on the Micropore AXF-1.  We were finished in less than an hour with all trials completed satisfactorily.  We were surprised at how simple Micropore’s equipment is to set up and operate

​​Customer, fragrance sector

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​​Micropore’s precision engineered products mean we don’t have problems with creaming or phase inversion any more.  We are working to convert manufacture of all our products to Micropore’s approach because of the ease of operation/cleaning and improved yields

​​Customer, personal care sector

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We approached Micropore after failing with others because we needed to replicate an in-flight problem.  Micropore delivered everything we hoped for and more.  The result was we were able to engineer a solution for major safety improvements and rapid implementation

​​Customer, aerospace sector

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