Microfluidic emulsification devices: from micrometer insights to large-scale food emulsion production

Droplet Microfluidic Devices: Working Principles, Fabrication Methods, and Scale-Up Applications

Compared with the conventional emulsification method, droplets generated within microfluidic devices exhibit distinct advantages such as precise control of fluids, exceptional monodispersity, uniform morphology, flexible manipulation, and narrow size distribution. These inherent benefits, including intrinsic safety, excellent heat and mass transfer capabilities, and large surface-to-volume ratio, have led to the widespread applications of droplet-based microfluidics across diverse fields, encompassing chemical engineering, particle synthesis, biological detection, diagnostics, emulsion preparation, and pharmaceuticals. However, despite its promising potential for versatile applications, the practical utilization of this technology in commercial and industrial is extremely limited to the inherently low production rates achievable within a single microchannel. Over the past two decades, droplet-based microfluidics has evolved significantly, considerably transitioning from a proof-of-concept stage to industrialization. And now there is a growing trend towards translating academic research into commercial and industrial applications, primarily driven by the burgeoning demands of various fields. This paper comprehensively reviews recent advancements in droplet-based microfluidics, covering the fundamental working principles and the critical aspect of scale-up integration from working principles to scale-up integration. Based on the existing scale-up strategies, the paper also outlines the future research directions, identifies the potential opportunities, and addresses the typical unsolved challenges.

Recent progress on Pickering emulsion stabilized essential oil added biopolymer-based film for food packaging applications: A review

Nowadays food safety and protection are a growing concern for food producers and food industry. The stability of food-grade materials is key in food processing and shelf life. Pickering emulsions (PEs) have gained significant attention in food regimes owing to their stability enhancement of food specimens. PE can be developed by high and low-energy methods. The use of PE in the food sector is completely safe as it uses solid biodegradable particles to stabilize the oil in water and it also acts as an excellent carrier of essential oils (EOs). EOs are useful functional ingredients, the inclusion of EOs in the packaging film or coating formulation significantly helps in the improvement of the shelf life of the packed food item. The highly volatile nature, limited solubility and ease of oxidation in light of EOs restricts their direct use in packaging. In this context, the use of PEs of EOs is suitable to overcome most of the challenges, Therefore, recently there have been many papers published on PEs of EOs including active packaging film and coatings and the obtained results are promising. The current review amalgamates these studies to inform about the chemistry of PEs followed by types of stabilizers, factors affecting the stability and different high and low-energy manufacturing methods. Finally, the review summarizes the recent advancement in PEs-added packaging film and their application in the enhancement of shelf life of food.

Glass Microdroplet Generator for Lipid-Based Double Emulsion Production

Microfluidics offers a highly controlled and reproducible route to synthesize lipid vesicles. In recent years, several microfluidic approaches have been introduced for this purpose, but double emulsions, such as Water-in-Oil-in-Water (W/O/W) droplets, are preferable to produce giant vesicles that are able to maximize material encapsulation. Flow focusing (FF) is a technique used to generate double emulsion droplets with high monodispersity, a controllable size, and good robustness. Many researchers use polydimethylsiloxane as a substrate material to fabricate microdroplet generators, but it has some limitations due to its hydrophobicity, incompatibility with organic solvents, and the molecular adsorption on the microchannel walls. Thus, specific surface modification and functionalization steps, which are uncomfortable to perform in closed microchannels, are required to overcome these shortcomings. Here, we propose glass as a material to produce a chip with a six-inlet junction geometry. The peculiar geometry and the glass physicochemical properties allow for W/O/W droplet formation without introducing microchannel wall functionalization and using a variety of reagents and organic solvents. The robust glass chip can be easily cleaned and used repeatedly, bringing advantages in terms of cost and reproducibility in emulsion preparation.

Starch-based particles as stabilizers for Pickering emulsions: modification, characteristics, stabilization, and applications

The potential utilization of starch as a particle-based emulsifier in the preparation of Pickering emulsions is gaining interest within the food industry. Starch is an affordable and abundant functional ingredient, which makes it an excellent candidate for the stabilization of Pickering emulsions. This review article focuses on the formation, stabilization, and properties of Pickering emulsions formulated using starch-based particles and their derivatives. First, methods of isolating and modifying starch-based particles are highlighted. The key parameters governing the properties of starch-stabilized Pickering emulsions are then discussed, including the concentration, size, morphology, charge, and wettability of the starch-based particles, as well as the type and size of the oil droplets. The physicochemical mechanisms underlying the ability of starch-based particles to form and stabilize Pickering emulsions are also discussed. Starch-based Pickering emulsions tend to be more resistant to coalescence than conventional emulsions, which is useful for some food applications. Potential applications of starch-stabilized Pickering emulsions are reviewed, as well as recent studies on their gastrointestinal fate. The information provided may stimulate the utilization of starch-based Pickering emulsions in food and other industries.

Computational fluid dynamics simulation of two-phase flow patterns in a serpentine microfluidic device

In the current research work, the flow behavior of a liquid-liquid extraction (LLE) process in a serpentine microchannel was analyzed. The simulation was performed using a 3D model and the results were found to be consistent with experimental data. The impact of the flow of chloroform and water on the flow model was also examined. The data indicate that once the aqua and organic phases flow rates are low and similar, a slug flow pattern is observed. However, as the overall flow rate raises, the slug flow transforms into parallel plug flow or droplet flow. An increment in the aqua flows while maintaining a constant organic phase flow rate results in a transition from slug flow to either droplet flow or plug flow. Finally, the patterns of flow rate in the serpentine micro-channel were characterized and depicted. The results of this study will provide valuable insights into the behavior of two-phase flow patterns in serpentine microfluidic devices. This information can be used to optimize the design of microfluidic devices for various applications. Furthermore, the study will demonstrate the applicability of CFD simulation in investigating the behavior of fluids in microfluidic devices, which can be a cost-effective and efficient alternative to experimental studies.

Design insights for upscaling spontaneous microfluidic emulsification devices based on behavior of the Upscaled Partitioned EDGE device

Microfluidic emulsification has the potential to produce emulsions with very controlled droplet sizes in a subtle manner. To support in unleashing this potential, we provide guidelines regarding upscaling based on the performance of Upscale Partitioned EDGE (UPE) devices, using rapeseed oil as the to-be-dispersed phase and whey proteins as the emulsifier. The UPE_5x1 device (11,000 droplet formation units (DFUs) of 5 × 1 µm) produced 3.5-µm droplets (CV 3.2 %) at 0.3 mL/h; UPE_10x2 (8,000 DFUs of 10 × 2 µm) produced 7-µm droplets (CV 3.2 %) at 0.5 mL/h, and at higher pressures, 32-µm droplets (CV 3-4 %) at 4 mL/h. These productivities are relatively high compared to those of other devices reported in literature (e.g., Microchannel, Tsukuba and Millipede, Harvard). Based on these results, and on others from literature, we conclude that: (1) the continuous phase channel dimensions need to be chosen such that they allow for gradual filling of this channel with droplets without decreasing the pressure over the droplet formation units significantly; (2) the dispersed phase supply channel design should create a wide stable droplet formation pressure range to increase productivity; and (3) higher productivities can be obtained through the choice of the ingredients used; low viscosity dispersed phase and an emulsifier that increases the interfacial tension without negatively affecting device wettability is preferred (e.g., whey protein outperforms Tween 20). These results and design guidelines are expected to contribute to the first food emulsion products prepared with microfluidics.

Designable microfluidic ladder networks from backstepping microflow analysis for mass production of monodisperse microdroplets

Controllable mass production of monodisperse droplets plays a key role in numerous fields ranging from scientific research to industrial application. Microfluidic ladder networks show great potential in mass production of monodisperse droplets, but their design with uniform microflow distribution remains challenging due to the lack of a rational design strategy. Here an effective design strategy based on backstepping microflow analysis (BMA) is proposed for the rational development of microfluidic ladder networks for mass production of controllable monodisperse microdroplets. The performance of our BMA rule for rational microfluidic ladder network design is demonstrated by using an existing analogism-derived rule that is widely used for the design of microfluidic ladder networks as the control group. The microfluidic ladder network designed by the BMA rule shows a more uniform flow distribution in each branch microchannel than that designed by the existing rule, as confirmed by single-phase flow simulation. Meanwhile, the microfluidic ladder network designed by the BMA rule allows mass production of droplets with higher size monodispersity in a wider window of flow rates and mass production of polymeric microspheres from such highly monodisperse droplet templates. The proposed BMA rule provides new insights into the microflow distribution behaviors in microfluidic ladder networks based on backstepping microflow analysis and provides a rational guideline for the efficient development of microfluidic ladder networks with uniform flow distribution for mass production of highly monodisperse droplets. Moreover, the BMA method provides a general analysis strategy for microfluidic networks with parallel multiple microchannels for rational scale-up.

Membrane Emulsification-A Novel Solution for Treatment and Reuse of Produced Water from Oil Field

Produced water (PW) is, by volume, the largest waste product of the oil- and gas-exploration industry and contains pollutants such as hydrocarbons and heavy metals. To meet the stringent environmental regulations, PW must be treated before discharging into the environment. The current study proposes a novel treatment method where PW is used to prepare oil-in-water emulsion with potential applications within the oil-exploration industry. The emulsions are prepared by applying hollow fiber membrane emulsification (ME) on PW, which inherently contains oil, as to-be-dispersed phase. The results demonstrate that the average droplet size of the emulsions is a function of pressure applied on to-be-dispersed phase and could be customized from 0.24 to 0.65 µm by varying the pressure from 0.25 to 1 bar, respectively. Stability of the emulsions was verified under high pressure and a temperature and storage period of more than 24 h. The calculations showed that an ME unit with <100 kg weight and <1 m3 volume is appropriate to transform the daily average volume of PW from the Danish part of the North Sea into the emulsions. The study provides a novel route, which also complies well with the requirements (low-weight and small spatial footprints) of the offshore oil rigs, to treat and reuse PW within the oil production process and, therefore, eliminates its environmental footprint.

Nanotechnology for a Sustainable Future: Addressing Global Challenges with the International Network4Sustainable Nanotechnology

Nanotechnology has important roles to play in international efforts in sustainability. We discuss how current and future capabilities in nanotechnology align with and support the United Nations' Sustainable Development Goals. We argue that, as a field, we can accelerate the progress toward these goals both directly through technological solutions and through our special interdisciplinary skills in communication and tackling difficult challenges. We discuss the roles of targeting solutions, technology translation, the circular economy, and a number of examples from national efforts around the world in reaching these goals. We have formed a network of leading nanocenters to address these challenges globally and seek to recruit others to join us.

Droplet Microfluidics for Food and Nutrition Applications

Droplet microfluidics revolutionizes the way experiments and analyses are conducted in many fields of science, based on decades of basic research. Applied sciences are also impacted, opening new perspectives on how we look at complex matter. In particular, food and nutritional sciences still have many research questions unsolved, and conventional laboratory methods are not always suitable to answer them. In this review, we present how microfluidics have been used in these fields to produce and investigate various droplet-based systems, namely simple and double emulsions, microgels, microparticles, and microcapsules with food-grade compositions. We show that droplet microfluidic devices enable unprecedented control over their production and properties, and can be integrated in lab-on-chip platforms for in situ and time-resolved analyses. This approach is illustrated for on-chip measurements of droplet interfacial properties, droplet-droplet coalescence, phase behavior of biopolymer mixtures, and reaction kinetics related to food digestion and nutrient absorption. As a perspective, we present promising developments in the adjacent fields of biochemistry and microbiology, as well as advanced microfluidics-analytical instrument coupling, all of which could be applied to solve research questions at the interface of food and nutritional sciences.

Application of microfluidic technology in food processing

Microfluidic technology is interdisciplinary with a diversity of applications including in food processing. The rapidly growing global population demands more advanced technologies in food processing to produce more functional and safer food, and for such processing microfluidic devices are a popular choice. This review critically critiques the state-of-the-art designs of microfluidic devices and their applications in food processing, and identifies the key research trends and future research directions for maximizing the value of microfluidic technology. Capillary, planar, and terrace droplet generation systems are currently used in the design of microfluidic devices, each with their strengths and weaknesses as applied in food processing, for emulsification, food safety measurements, and bioactive compound extraction. Conventional channel-based microfluidic devices are prone to clogging, and have high labor costs and low productivity, and their "directional pressure" restricts scaling-up capabilities. These disadvantages can be overcome by using "inside-out centrifugal force" and the new generation continuous flow thin-film microfluidic Vortex Fluidic Device (VFD) which facilitates translating laboratory processing into commercial products. Also highlighted is controlling protein-polysaccharide interactions and the applications of the produced ingredients in food formulations as targets for future development in the field.

Vortex fluidics mediated non-covalent physical entanglement of tannic acid and gelatin for entrapment of nutrients

We have developed a simple process for the entrapment of nutrients in shear stress induced non-covalent physically entangled tannic acid-gelatin gel in a thin film vortex fluidic device (VFD) operating under continuous flow. This allows control of the porosity and surface area of the pores in order to improve the nutrient entrapment capacity. The VFD microfluidic platform simplifies the processing procedure of physically entangled biopolymers, as a time and cost saving one-step process devoid of any organic solvents, in contrast to the conventional homogenization process, which is also inherently complex, involving multiple-step processing. Moreover, the use of homogenization (as a benchmark to entrap nutrients) afforded much larger porosity and surface area of pores, with lower entrapment capacity of nutrients. Overall, the VFD processing provides a new alternative, bottom-up approach for easy, scalable processing for materials with a high nutrient entrapment capacity.

All-graphene-based open fluidics for pumpless, small-scale fluid transport via laser-controlled wettability patterning

Open microfluidics have emerged as a low-cost, pumpless alternative strategy to conventional microfluidics for delivery of fluid for a wide variety of applications including rapid biochemical analysis and medical diagnosis. However, creating open microfluidics by tuning the wettability of surfaces typically requires sophisticated cleanroom processes that are unamenable to scalable manufacturing. Herein, we present a simple approach to develop open microfluidic platforms by manipulating the surface wettability of spin-coated graphene ink films on flexible polyethylene terephthalate via laser-controlled patterning. Wedge-shaped hydrophilic tracks surrounded by superhydrophobic walls are created within the graphene films by scribing micron-sized grooves into the graphene with a CO2 laser. This scribing process is used to make superhydrophobic walls (water contact angle ∼160°) that delineate hydrophilic tracks (created through an oxygen plasma pretreatment) on the graphene for fluid transport. These all-graphene open microfluidic tracks are capable of transporting liquid droplets with a velocity of 20 mm s-1 on a level surface and uphill at elevation angles of 7° as well as transporting fluid in bifurcating cross and tree branches. The all-graphene open microfluidic manufacturing technique is rapid and amenable to scalable manufacturing, and consequently offers an alternative pumpless strategy to conventional microfluidics and creates possibilities for diverse applications in fluid transport.

Formation of alginate microspheres prepared by optimized microfluidics parameters for high encapsulation of bioactive molecules

Drug delivery systems such as microspheres have shown potential in releasing biologicals effectively for tissue engineering applications. Microfluidic systems are especially attractive for generating microspheres as they produce microspheres of controlled-size and in low volumes, using micro-emulsion processes. However, the flow rate dependency on the encapsulation of molecules at a microscale is poorly understood. In particular, the flow rate and pressure parameters might influence the droplet formation and drug encapsulation efficiency. We evaluated the parameters within a two-reagent flow focusing microfluidic chip under continuous formation of hydrogel particles using a flourinated oil and an ionic crosslinkable alginate hydrogel. Fluorescein isothiocyanate-dextran sulfate (FITC-dextran sulfate MW: 40 kDa) was used to evaluate the variation of the encapsulation efficiency with the flow parameters, optimizing droplets and microsphere formation. The ideal flow rates allowing for maximum encapsulation efficiency, were utilised to form bioactive microspheres by delivering transforming growth factor beta-3 (TGFβ-3) in cell culture media. Finally, we evaluated the potential of microfluidic-formed microspheres to be included within biological environments. The biocompatibility of the microspheres was tested over 28 days using adult human mesenchymal stem cells (hMSCs). The release profile of the growth factors from microspheres showed a sustained release in media, after an initial burst, up to 30 days. The metabolic activity of the cells cultured in the presence of the microspheres was similar to controls, supporting the biocompatibility of this approach. The fine-tuned parameters for alginate hydrogel to form microspheres have potential in encapsulating and preserving functional structure of bioactive agents for future tissue engineering applications.

The Importance of Interfacial Tension in Emulsification: Connecting Scaling Relations Used in Large Scale Preparation with Microfluidic Measurement Methods

This paper starts with short descriptions of emulsion preparation methods used at large and smaller scales. We give scaling relations as they are generally used, and focus on the central role that interfacial tension plays in these relations. The actual values of the interfacial tension are far from certain given the dynamic behavior of surface-active components, and the lack of measurement methods that can be applied to conditions as they occur during large-scale preparation. Microfluidic techniques are expected to be very instrumental in closing this gap. Reduction of interfacial tension resulting from emulsifier adsorption at the oil-water interface is a complex process that consists of various steps. We discuss them here, and present methods used to probe them. Specifically, methods based on microfluidic tools are of great interest to study short droplet formation times, and also coalescence behavior of droplets. We present the newest insights in this field, which are expected to bring interfacial tension observations to a level that is of direct relevance for the large-scale preparation of emulsions, and that of other multi-phase products.

Microfluidics Used as a Tool to Understand and Optimize Membrane Filtration Processes

Membrane filtration processes are best known for their application in the water, oil, and gas sectors, but also in food production they play an eminent role. Filtration processes are known to suffer from a decrease in efficiency in time due to e.g., particle deposition, also known as fouling and pore blocking. Although these processes are not very well understood at a small scale, smart engineering approaches have been used to keep membrane processes running. Microfluidic devices have been increasingly applied to study membrane filtration processes and accommodate observation and understanding of the filtration process at different scales, from nanometer to millimeter and more. In combination with microscopes and high-speed imaging, microfluidic devices allow real time observation of filtration processes. In this review we will give a general introduction on microfluidic devices used to study membrane filtration behavior, followed by a discussion of how microfluidic devices can be used to understand current challenges. We will then discuss how increased knowledge on fundamental aspects of membrane filtration can help optimize existing processes, before wrapping up with an outlook on future prospects on the use of microfluidics within the field of membrane separation.

512-Channel Geometric Droplet-Splitting Microfluidic Device by Injection of Premixed Emulsion for Microsphere Production

We present a 512-channel geometric droplet-splitting microfluidic device that involves the injection of a premixed emulsion for microsphere production. The presented microfluidic device was fabricated using conventional photolithography and polydimethylsiloxane casting. The fabricated microfluidic device consisted of 512 channels with 256 T-junctions in the last branch. Five hundred and twelve microdroplets with a narrow size distribution were produced from a single liquid droplet. The diameter and size distribution of prepared micro water droplets were 35.29 µm and 8.8% at 10 mL/h, respectively. Moreover, we attempted to prepare biocompatible microspheres for demonstrating the presented approach. The diameter and size distribution of the prepared poly (lactic-co-glycolic acid) microspheres were 6.56 µm and 8.66% at 10 mL/h, respectively. To improve the monodispersity of the microspheres, we designed an additional post array part in the 512-channel geometric droplet-splitting microfluidic device. The monodispersity of the microdroplets prepared with the microfluidic device combined with the post array part exhibited a significant improvement.

Microtechnological Tools to Achieve Sustainable Food Processes, Products, and Ingredients

One of the major challenges we face as humankind is supplying a growing world population with sufficient and healthy foods. Although from a worldwide perspective sufficient food is produced, locally, the situation can be dire. Furthermore, the production needs to be increased in a sustainable manner for future generations, which also implies prevention of food waste, and making better use of the available resources. How to contribute to this as food technologists is an ultimate question, especially since the tools that can investigate processes at relevant time scales, and dimensions, are lacking. Here we propose the use of microtechnology and show examples of how this has led to new insights in the fields of ingredient isolation (filtration), and emulsion/foam formation, which will ultimately lead to better-defined products. Furthermore, microfluidic tools have been applied for testing ingredient functionality, and for this, various examples are discussed that will expectedly contribute to making better use of more sustainably sourced starting materials (e.g., novel protein sources). This review will wrap up with a section in which we discuss future developments. We expect that it will be possible to link food properties to the effects that foods create in vivo. We thus expand the scope of this review that is technical in nature, toward physiological functionality, and ultimately to rational food design that is targeted to improve human health.

Advances of spontaneous emulsification and its important applications in enhanced oil recovery process

Emulsions, including oil-in-water (O/W) and water-in-oil (W/O) emulsions, can play important roles in both controlling reservoir conformance and displacing residual oil for enhanced oil recovery (EOR) projects. However, current methods, like high-shear mixing, high-pressure homogenizing, sonicators and others, often use lots of extra energy to prepare the emulsions with high costs but very low energy efficiency. In recent decades, spontaneous emulsification methods, which allow one to create micro- and nano-droplets with very low or even no mechanical energy input, have been launched as an overall less expensive and more efficient alternatives to current high extra energy methods. Herein, we primarily review the basic concepts on spontaneous emulsification, including mechanisms, methods and influenced parameters, which are relevant for fundamental applications for industrials. The spontaneity of the emulsification process is influenced by the following variables: surfactant structure, concentration and initial location, oil phase composition, addition of co-surfactant and non-aqueous solvent, as well as salinity and temperature. Then, we focus on the description of importance for emulsions in EOR processes from advances and categories to improving oil recovery mechanisms, including both sweep efficiency and displacement efficiency aspects. Finally, we systematically address the applications and outlooks based on the use of spontaneous emulsification in the practical oil reservoirs for EOR processes, in which conventional, heavy, high-temperature, high-salinity and low-permeability oil reservoirs, as well as wastewater treatments after EOR processes are involved.

Application of Microfluidics in the Production and Analysis of Food Foams

Emulsifiers play a key role in the stabilization of foam bubbles. In food foams, biopolymers such as proteins are contributing to long-term stability through several effects such as increasing bulk viscosity and the formation of viscoelastic interfaces. Recent studies have identified promising new stabilizers for (food) foams and emulsions, for instance biological particles derived from water-soluble or water-insoluble proteins, (modified) starch as well as chitin. Microfluidic platforms could provide a valuable tool to study foam formation on the single-bubble level, yielding mechanistic insights into the formation and stabilization (as well as destabilization) of foams stabilized by these new stabilizers. Yet, the recent developments in microfluidic technology have mainly focused on emulsions rather than foams. Microfluidic devices have been up-scaled (to some extent) for large-scale emulsion production, and also designed as investigative tools to monitor interfaces at the (sub)millisecond time scale. In this review, we summarize the current state of the art in droplet microfluidics (and, where available, bubble microfluidics), and provide a perspective on the applications for (food) foams. Microfluidic investigations into foam formation and stability are expected to aid in optimization of stabilizer selection and production conditions for food foams, as well as provide a platform for (large-scale) production of monodisperse foams.

Microfluidic Systems for Droplet Generation in Aqueous Continuous Phases: A Focus Review

Microfluidics is one of the most fascinating fields that researchers have been trying to apply in a large number of scientific disciplines over the past two decades. Among them, the discipline of food and pharmaceutical formulation encountered several obstacles when combining microfluidics with aqueous media. Indeed, the physical properties of liquids at micrometric volumes being particular, the droplet generation within microfluidic devices is a big challenge to be met. This focus review is intended to be an initiation for those who would like to generate microdroplets in microfluidic systems involving aqueous continuous phases. It provides a state-of-the-art look at such systems while focusing on the microfluidic devices used, their applications to form a wide variety of emulsions and particles, and the key role held by the interface between the device channels and the emulsion. This review also leads to reflections on new materials that can be used in microfluidic systems with aqueous continuous phases.

Monodisperse droplet formation by spontaneous and interaction based mechanisms in partitioned EDGE microfluidic device

The partitioned EDGE droplet generation device is known for its’ high monodisperse droplet formation frequencies in two distinct pressure ranges, and an interesting candidate for scale up of microfluidic emulsification devices. In the current study, we test various continuous and dispersed phase properties and device geometries to unravel how the device spontaneously forms small monodisperse droplets (6–18 μm) at low pressures, and larger monodisperse droplets (>28 μm) at elevated pressures. For the small droplets, we show that the continuous phase inflow in the droplet formation unit largely determines droplet formation behaviour and the resulting droplet size and blow-up pressure. This effect was not considered as a factor of significance for spontaneous droplet formation devices that are mostly characterised by capillary numbers in literature. We then show for the first time that the formation of larger droplets is caused by physical interaction between neighbouring droplets, and highly dependent on device geometry. The insights obtained here are an essential step toward industrial emulsification based on microfluidic devices.

Wetting controls of droplet formation in step emulsification

The formation of droplets is ubiquitous in many natural and industrial processes and has reached an unprecedented level of control with the emergence of milli- and microfluidics. Although important insight into the mechanisms of droplet formation has been gained over the past decades, a sound understanding of the physics underlying this phenomenon and the effect of the fluid's flow and wetting properties on the droplet size and production rate is still missing, especially for the widely applied method of step emulsification. In this work, we elucidate the physical controls of microdroplet formation in step emulsification by using the wetting of fluidic channels as a tunable parameter to explore a broad set of emulsification conditions. With the help of high-speed measurements, we unequivocally show that the final droplet pinch-off is triggered by a Rayleigh-Plateau-type instability. The droplet size, however, is not determined by the Rayleigh-Plateau breakup, but by the initial wetting regime, where the fluid's contact angle plays a crucial role. We develop a physical theory for the wetting process, which closely describes our experimental measurements without invoking any free fit parameter. Our theory predicts the initiation of the Rayleigh-Plateau breakup and the transition from dripping to jetting as a function of the fluid's contact angle. Additionally, the theory solves the conundrum why there is a minimal contact angle of α = 2π/3 = 120° for which droplets can form.

Formation and purification of tailored liposomes for drug delivery using a module-based micro continuous-flow system

Liposomes are lipid based bilayer vesicles that can encapsulate, deliver and release low-soluble drugs and small molecules to a specific target site in the body. They are currently exploited in several nanomedicine formulations. However, their development and application is still limited by expensive and time-consuming process development and production methods. Therefore, to exploit these systems more effectively and support the rapid translation of new liposomal nanomedicines from bench to bedside, new cost-effective and scalable production methods are needed. We present a continuous process flow system for the preparation, modification and purification of liposomes which offers lab-on-chip scale production. The system was evaluated for a range of small vesicles (below 300 nm) varying in lipid composition, size and charge; it offers effective and rapid nanomedicine purification with high lipid recovery (> 98%) combined with effective removal of non-entrapped drug (propofol >95% reduction of non-entrapped drug present) or protein (ovalbumin >90% reduction of OVA present) and organic solvent (ethanol >95% reduction) in less than 4 minutes. The key advantages of using this bench-top, rapid, process development tool are the flexible operating conditions, interchangeable membranes and scalable high-throughput yields, thereby offering simultaneous manufacturing and purification of nanoparticles with tailored surface attributes.

Emulsification in novel ultrasonic cavitation intensifying bag reactors

Cavitation Intensifying Bags (CIBs), a novel reactor type for use with ultrasound, have been recently proposed as a scaled-up microreactor with increased energy efficiencies. We now report on the use of the CIBs for the preparation of emulsions out of hexadecane and an SDS aqueous solution. The CIBs have been designed in such a way that cavitation effects created by the ultrasound are increased. It was found that the CIBs were 60 times more effective in breaking up droplets than conventional bags, therewith showing a proof of principle for the CIBs for the preparation of emulsions. Droplets of 0.2μm could easily be obtained. To our knowledge, no other technology results in the same droplet size more easily in terms of energy usage. Without depending on the wettability changes of the membrane, the CIBs score similarly as membrane emulsification, which is the most energy friendly emulsification method known in literature. Out of the frequencies used, 37kHz was found to require the lowest treatment time. The treatment time decreased at higher temperatures. While the energy usage in the current non-optimised experiments was on the order of 10⁷-10⁹J/m³, which is comparable to that of a high-pressure homogenizer, we expect that the use of CIBs for the preparation of fine emulsions can still be improved considerably. The process presented can be applied for other uses such as water treatment, synthesis of nanomaterials and food processing.

Apparent Interfacial Tension Effects in Protein Stabilized Emulsions Prepared with Microstructured Systems

Proteins are mostly used to stabilize food emulsions; however, production of protein containing emulsions is notoriously difficult to capture in scaling relations due to the complex behavior of proteins in interfaces, in combination with the dynamic nature of the emulsification process. Here, we investigate premix membrane emulsification and use the Ohnesorge number to derive a scaling relation for emulsions prepared with whey protein, bovine serum albumin (BSA), and a standard emulsifier Tween 20, at various concentrations (0.1%, 0.5%, 1.25% and 2%). In the Ohnesorge number, viscous, inertia, and interfacial tension forces are captured, and most of the parameters can be measured with great accuracy, with the exception of the interfacial tension. We used microfluidic Y-junctions to estimate the apparent interfacial tension at throughputs comparable to those in premix emulsification, and found a unifying relation. We next used this relation to plot the Ohnesorge number versus P-ratio defined as the applied pressure over the Laplace pressure of the premix droplet. The measured values all showed a decreasing Ohnesorge number at increasing P-ratio; the differences between regular surfactants and proteins being systematic. The surfactants were more efficient in droplet size reduction, and it is expected that the differences were caused by the complex behavior of proteins in the interface (visco-elastic film formation). The differences between BSA and whey protein were relatively small, and their behavior coincided with that of low Tween concentration (0.1%), which deviated from the behavior at higher concentrations.

Microfluidic EDGE emulsification: the importance of interface interactions on droplet formation and pressure stability

The fact that interactions of components with interfaces can influence processes is well-known; e.g. deposit accumulation on heat exchangers and membrane fouling lead to additional resistances against heat and mass transfer, respectively. In microfluidic emulsification, the situation is even more complex. Component accumulation at the liquid/liquid interface is necessary for emulsion stability, while undesired at the solid/liquid interface where it may change wettability. For successful emulsification both aspects need to be controlled, and that is investigated in this paper for o/w emulsification with microfluidic EDGE devices. These devices were characterised previously, and can be used to detect small wettability changes through e.g. the pressure stability of the device. We used various oil/emulsifier combinations (alkanes, vegetable oil, surfactants and proteins) and related droplet size and operational pressure stability to component interactions with the solid surface and liquid interface. Surfactants with a strong interaction with glass always favour emulsification, while surfactants that have week interactions with the surface can be replaced by vegetable oil that interacts strongly with glass, resulting in loss of emulsification. Our findings clearly show that an appropriate combination of construction material and emulsion components is needed to achieve successful emulsification in microfluidic EDGE devices.

Linking Findings in Microfluidics to Membrane Emulsification Process Design: The Importance of Wettability and Component Interactions with Interfaces

In microfluidics and other microstructured devices, wettability changes, as a result of component interactions with the solid wall, can have dramatic effects. In emulsion separation and emulsification applications, the desired behavior can even be completely lost. Wettability changes also occur in one phase systems, but the effect is much more far-reaching when using two-phase systems. For microfluidic emulsification devices, this can be elegantly demonstrated and quantified for EDGE (Edge-base Droplet GEneration) devices that have a specific behavior that allows us to distinguish between surfactant and liquid interactions with the solid surface. Based on these findings, design rules can be defined for emulsification with any micro-structured emulsification device, such as direct and premix membrane emulsification. In general, it can be concluded that mostly surface interactions increase the contact angle toward 90°, either through the surfactant, or the oil that is used. This leads to poor process stability, and very limited pressure ranges at which small droplets can be made in microfluidic systems, and cross-flow membrane emulsification. In a limited number of cases, surface interactions can also lead to lower contact angles, thereby increasing the operational stability. This paper concludes with a guideline that can be used to come to the appropriate combination of membrane construction material (or any micro-structured device), surfactants and liquids, in combination with process conditions.