Emulsification in turbulent flow:

Physicochemical and Functional Properties of Membrane-Fractionated Heat-Induced Pea Protein Aggregates

This study was carried out to investigate the effect of heat pre-treatment of pea proteins at different pH values on the formation of functional protein aggregates. A 10% (w/v) aqueous mixture of pea protein concentrate (PPC) was adjusted to pH 3.0, 5.0, 7.0, or 9.0 followed by heating at 100°C for 30 min, cooled and centrifuged. The supernatant was sequentially passed through 30 and 50 kDa molecular weight cut-off membranes to collect the <30, 30–50, and >50 kDa fractions. The >50 kDa fractions from pH 3.0 (FT3), 5.0 (FT5), 7.0 (FT7), and 9.0 (FT9) treatments had >60% protein content in contrast to the ≤20% for the <30 and 30–50 kDa fractions. Therefore, the >50 kDa fractions were collected and then compared to the untreated PPC for some physicochemical and functional properties. Protein aggregation was confirmed as the denaturation temperature for FT3 (124.30°C), FT5 (190.66^oC), FT7 (206.33^oC) and FT9 (203.17^oC) was significantly (p < 0.05) greater than that of PPC (74.45^oC). Scanning electron microscopy showed that FT5 had a compact structure like PPC while FT3, FT7, and FT9 contained a more continuous network. In comparison to PPC, the >50 kDa fractions showed improved solubility (>60%), oil holding capacity (~100%), protein content (~7%), foam capacity (>10%), foam stability (>7%), water holding capacity (>16%) and surface hydrophobicity (~50%). Least gelation concentration of PPC (18%), FT3 (25%), FT5 (22%), FT7 (22%), and FT9 (25%) was improved to 16, 18, 20, 16, and 18%, respectively, after addition of NaCl.

Towards a Standard Method for Estimating Fragmentation Rates in Emulsification Experiments

The fragmentation rate function connects the fundamental drop breakup process with the resulting drop size distribution and is central to understanding or modeling emulsification processes. There is a large interest in being able to reliably measure it from an emulsification experiment, both for generating data for validating theoretical fragmentation rate function suggestions and as a tool for studying emulsification processes. Consequently, several methods have been suggested for measuring fragmentation rates based on emulsion experiments. Typically, each study suggests a new method that is rarely used again. The lack of an agreement on a standard method has become a substantial challenge. This contribution critically and systematically analyses four influential suggestions of how to measure fragmentation rate in terms of validity, reliability, and sensitivity to method assumptions. The back-calculation method is identified as the most promising—high reliability and low sensitivity to assumption—whereas performing a non-linear regression on a parameterized model (as commonly suggested) is unsuitable due to its high sensitivity. The simplistic zero-order method is identified as an interesting supplemental tool that could be used for qualitative comparisons but not for quantification.

Continuous Production of Water-Based UV-Curable Polyurethane Dispersions Using Static Mixers and a Rotor-Stator Mixer

UV-curable polyurethane dispersions (UV-PUDs) have applications in coatings for a variety of materials. Historically, the neutralization and dispersion steps of the UV-PUD production process have been performed in batch. However, continuous processing might reduce capital and operating costs, improve the dispersion characteristics, and facilitate scale-up. Static mixers and inline high-shear mixers are able to provide the necessary shear forces to obtain miniemulsions. The production of a UV-PUD is therefore studied in a continuous setup, whereby the neutralization step is performed in static mixers and the dispersion step is performed either in static mixers or in a high-shear mixer. The influence of the prepolymer temperature, mixing energy, and feed flow rate on the particle size and stability of the UV-PUD particles in water is explored. The results show that the neutralization step is mixing-sensitive, and the temperature of the neutralized prepolymer influences the particle size in the dispersion process. The amount of shear force applied during the dispersion step has a limited effect on the particle size. UV-PU dispersions with an average particle size below 80 nm and PDI below 0.1 are obtained with static mixers or in an inline rotor-stator mixer, at flow rates of 5.2 and 7.2 L/h, respectively. This research demonstrates that continuous processing using static mixers and high-shear mixing is a viable option for the neutralization and dispersion of UV-PUDs.

Experimental Methods for Measuring the Breakup Frequency in Turbulent Emulsification: A Critical Review

The growing interest in using population balance modeling to describe emulsification processes has spurred an interest in experimentally measuring the breakup frequency. This contribution classifies, compares, and critically reviews the different methods that have been suggested for measuring the breakup frequency, applicable to emulsification devices. Two major approaches can be seen in previous studies. The first is ‘single drop breakup experiment’-based studies, which estimate the breakup frequency by observing the fate of individual drops. The second approach involves ‘emulsification experiment’-based studies, which combine measured drop-size distributions with assumptions to allow for estimations of the breakup frequency. This second approach can be further subdivided in three types: Parametric determination, inverse self-similarity-based methods, and direct back-calculation methods. Each of these methods are reviewed in terms of their implementation, reliability, and validity. Suggestions of methodological considerations for future studies are given for each class, together with more general suggestions for further investigations. The overall objective is to provide emulsification researchers with background information when choosing which method to use for measuring the breakup frequency and with support when setting up experiments and data evaluation procedures.

Emulsion Formation by Homogenization: Current Understanding and Future Perspectives

Emulsion formation by homogenization is commonly used in food production and research to increase product stability and to design colloidal structures. High-energy methods such as high-pressure homogenizers and rotor–stator mixers are the two most common techniques. However, to what extent does the research community understand the emulsion formation taking place in these devices? This contribution attempts to answer this question through critically reviewing the scientific literature, starting with the hydrodynamics of homogenizers and continuing by reviewing drop breakup and coalescence. It is concluded that although research in this field has been ongoing for a century and has provided a substantial amount of empirical correlations and scaling laws, the fundamental understanding is still limited, especially in the case of emulsions with a high-volume fraction of the disperse phase, as seen in many food applications. These limitations in the current understanding are also used to provide future perspectives and suggest directions for further investigation.

A study of the effectiveness and energy efficiency of ultrasonic emulsification

Three essential experimental parameters in the ultrasonic emulsification process, namely sonication time, acoustic amplitude and processing volume, were individually investigated, theoretically and experimentally, and correlated to the emulsion droplet sizes produced. The results showed that with a decrease in droplet size, two kinetic regions can be separately correlated prior to reaching a steady state droplet size: a fast size reduction region and a steady state transition region. In the fast size reduction region, the power input and sonication time could be correlated to the volume-mean diameter by a power-law relationship, with separate power-law indices of -1.4 and -1.1, respectively. A proportional relationship was found between droplet size and processing volume. The effectiveness and energy efficiency of droplet size reduction was compared between ultrasound and high-pressure homogenisation (HPH) based on both the effective power delivered to the emulsion and the total electric power consumed. Sonication could produce emulsions across a broad range of sizes, while high-pressure homogenisation was able to produce emulsions at the smaller end of the range. For ultrasonication, the energy efficiency was higher at increased power inputs due to more effective droplet breakage at high ultrasound intensities. For HPH the consumed energy efficiency was improved by operating at higher pressures for fewer passes. At the laboratory scale, the ultrasound system required less electrical power than HPH to produce an emulsion of comparable droplet size. The energy efficiency of HPH is greatly improved at large scale, which may also be true for larger scale ultrasonic reactors.

Kinetics of the Change in Droplet Size during Nanoemulsion Formation

The evolution of droplet size during nanoemulsion formation is critical for the rational design of nanoemulsions in areas such as drug delivery and materials synthesis. In this article, we discuss the relative importance of various time scales involved in nanoemulsion formation and propose a population balance model for droplet breakup that takes into account the droplet's internal viscosity. The proposed model gives a qualitative agreement between average droplet size and polydispersity data for nanoemulsions prepared by high-pressure homogenization and ultrasonication. On the basis of these modeling results, we propose a correlation to obtain a parity plot for the droplet size data. We show that our model and correlation also work well with data from the existing literature. The proposed model and correlation can be used to guide future population balance studies and experimental preparation of nanoemulsions.

Steady-state droplet size in montmorillonite stabilised emulsions

The formation of hexadecane-in-water emulsions stabilised by montmorillonite platelets was studied. In this system the platelets form a monolayer around the droplets and the droplet size decreases with increasing platelet volume fraction. However, the number of platelets present exceeds that required for monolayer coverage. The kinetics of emulsification were investigated and coalescence of droplets during turbulent mixing was found to continue even after the droplets had reached their ultimate size. Non-spherical droplets, resulting from arrested coalescence, were not observed suggesting that particles may be desorbing from the interface during the turbulent flow. A kinetic model based on a competition between droplet break-up and coalescence, mediated by particle adsorption and desorption, reproduces experimental trends in droplet diameter. The model can be used to predict the most efficient formulation to minimise droplet diameters for given materials and mixing conditions and sheds light on the processes occurring during emulsification in this system.

Efficient emulsification of viscous oils at high drop volume fraction

It is shown experimentally in this study that the increase of drop volume fraction can be used as an efficient tool for emulsification of viscous oils in turbulent flow. In a systematic series of experiments, the effects of drop volume fraction and viscosity of the dispersed phase on the mean, d(32), and maximum, d(V95), diameters of the drops, formed during emulsification, are quantified. The volume fraction, Φ, of the dispersed oily phase is varied between 1% and 90%, and oils with viscosity varying between 3 and 10,000 mPa.s are studied. All experiments are performed at sufficiently high surfactant concentration, as to avoid possible drop-drop coalescence during emulsification. The analysis of the experimental data shows that there is a threshold drop volume fraction, Φ(TR), at which a transition from inertial turbulent regime into viscous turbulent regime of emulsification occurs, due to the increased overall viscosity of the emulsion. At Φ < Φ(TR), d(32) and d(V95) depend weakly on Φ and are well described by known theoretical expression for emulsification in inertial turbulent regime (Davies, Chem. Eng. Sci. 1985, 40, 839), which accounts for the effects of oil viscosity and interfacial tension. At Φ > Φ(TR), both d(32) and polydispersity of the formed emulsions decrease very significantly with the increase of Φ (for the oils with η(D) > 10 mPa.s). Thus, very efficient emulsification of the viscous oils is realized. Very surprisingly, a third regime of emulsification is observed in the range of concentrated emulsions with Φ > 75%, where the mean drop size and emulsion polydispersity are found experimentally to be very similar for all oils and surfactants studied-an experimental fact that does not comply with any of the existing models of drop breakup during emulsification. Possible mechanistic explanations of this result are discussed. The experimental data for semiconcentrated and concentrated emulsions with Φ > Φ(TR) are described by a simple scaling expression, which accounts for the effects of all main factors studied.

Rheology of emulsions

The review is devoted to the historical and modern understanding of rheological properties of emulsions in a broad range of concentration. In the limiting case of dilute emulsions, the discussion is based on the analogy and differences in properties of suspensions and emulsions. For concentrated emulsions, the main peculiarities of their rheological behaviour are considered. Different approaches to understand the concentration dependencies of viscosity are presented and compared. The effects of non-Newtonian flow curves and the apparent transition to yielding with increasing concentration of the dispersed phase are discussed. The problem of droplet deformation in shear fields is touched. The highly concentrated emulsions (beyond the limit of closest packing of spherical particles) are treated as visco-plastic media, and the principle features of their rheology (elasticity, yielding, concentration and droplet size dependencies) are considered. A special attention is paid to the problem of shear stability of drops of an internal phase starting from the theory of the single drop behaviour, including approaches for the estimation of drops' stability in concentrated emulsions. Polymer blends are also treated as emulsions, though taking into account their peculiarities due to the coexistence of two interpenetrated phases. Different theoretical models of deformation of polymer drops were discussed bearing in mind the central goal of predictions of the visco-elastic properties of emulsions as functions of the properties of individual components and the interfacial layer. The role of surfactants is discussed from the point of view of stability of emulsions in time and their special influence on the rheology of emulsions.