Emulsification

Emulsification is defined as a process of dispersing one liquid in a second immiscible liquid. For example, mixing oil into water. 

This can be achieved by mechanical means, such as shaking, microfluidic mixing, using a kitchen blender or homogeniser. If no emulsifier has been added, 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 mixed together.
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.

​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.  Further, our hygienic 100% stainless steel equipment gives clear benefits:

• 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.

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.

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 below, 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.

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Applications

Pharmaceuticals

Cosmetics, Fragrances and Skincare

Food and Beverages

Chromatography

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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, pharmaceutical sector

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Pharmaceutical sector

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​It was very clear from the outset, that there were great advantages to be gained by joining forces with Micropore Technologies

Customer, food sector

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Although initially sceptical due to inconclusive results using membrane technology in the past, the Micropore results quickly surpassed our expectations and delivered a viable alternative to our previous production methods

Customer, fragrance sector

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