Novel asymmetric through-hole array microfabricated on a silicon plate for formulating monodisperse emulsions

Upscaled Production of Satellite-Free Droplets: Step Emulsification with Deterministic Lateral Displacement

Step emulsification is a key technique for achieving scalable production of monodisperse emulsion droplets owing to its resilience to flow fluctuations. However, the persistent issue of satellite droplets, an inherent byproduct of main droplets, poses challenges for achieving truly uniform product sizes. In a previous study, we introduced a module with step-emulsifier nozzles upstream and deterministic lateral displacement (DLD) micropillar arrays downstream to generate satellite-free droplets at a low throughput. In this study, we demonstrate an upscaled parallelized setup with ten modules that were designed to produce satellite-free droplets. Each module integrated 100 step-emulsification nozzles in the upstream region with DLD micropillar arrays downstream. We conducted 3D flow simulations to ensure homogeneous distribution of the input fluids. Uniformly supplying an aqueous polyvinyl alcohol solution and an acrylate monomer as continuous and dispersed phases into the ten modules, the nozzles in each module exhibited a production rate of 539.5 ± 28.6 drop/s (n = 10). We successfully isolated the main droplets with a mean diameter of 66 μm and a coefficient of variation of 3.1% from satellite droplets with a mean diameter of 3 μm. The total throughput was 3.0 mL/h. The high yield and contamination-free features of our approach are promising for diverse industrial applications.

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.

Double emulsions with ultrathin shell by microfluidic step-emulsification

Double emulsions with ultrathin shells are important in some biomedical applications, such as controlled drug release. However, the existing production techniques require two or more manipulation steps, or more complicated channel geometry, to form thin-shell double emulsions. This work presents a novel microfluidic tri-phasic step-emulsification device, with an easily fabricated double-layer PDMS channel, for production of oil-in-oil-in-water and water-in-water-in-oil double emulsions in a single step. The shell thickness is controlled by the flow rates and can reach 1.4% of the μm-size droplet diameter. Four distinct emulsification regimes are observed depending on the experimental conditions. A theoretical model for the tri-phasic step-emulsification is proposed to predict the boundaries separating the four regimes of emulsification in plane of two dimensionless capillary numbers, Ca. The theory yields two coupled nonlinear differential equations that can be solved numerically to find the approximate shape of the free interfaces in the shallow (Hele-Shaw) microfluidic channel. This approximation is then used as the initial guess for the more accurate finite element method solution, showing very good agreement with the experimental findings. This study demonstrates the feasibility of co-flow step-emulsification as a promising method to production of double (and multiple) emulsions and micro-capsules with ultrathin shells of controllable thickness.

Protein-Stabilized Palm-Oil-in-Water Emulsification Using Microchannel Array Devices under Controlled Temperature

Microchannel (MC) emulsification for the preparation of monodisperse oil-in-water (O/W) and water-in-oil-in-water (W/O/W) emulsions containing palm oil as the oil phase was investigated for application as basic material solid/semi-solid lipid microspheres for delivery carriers of nutrients and drugs. Emulsification was characterized by direct observation of droplet generation under various operation conditions, as such, the effects of type and concentration of emulsifiers, emulsification temperature, MC structure, and flow rate of to-be-dispersed phase on droplet generation via MC were investigated. Sodium caseinate (SC) was confirmed as the most suitable emulsifier among the examined emulsifiers, and monodisperse O/W and W/O/W emulsions stabilized by it were successfully obtained with 20 to 40 µm mean diameter (d_m) using different types of MCs.

All-Fiber Measurement of Surface Tension Using a Two-Hole Fiber

An all-fiber approach is presented to measure surface tension. The experimental realization relies on the use of a specialty fiber, a so-called two-hole fiber (THF), which serves a two-fold purpose: providing a capillary channel to produce bubbles while having the means to measure the power reflected at the end facet of the fiber core. We demonstrate that provided a controlled injection of gas into the hollow channels of the THF, surface tension measurements are possible by simply tracking the Fresnel reflection at the distal end of the THF. Our results show that the characteristic times involved in the bubble formation process, from where the surface tension of the liquids under test is retrieved, can be measured from the train of pulses generated by the continuous formation and detachment of bubbles.

Mass spectrometric imaging of localization of fat molecules in water-in-oil emulsions containing semi-solid fat

Firstly, we report the localization analysis of the lipid components of a water-in-oil (W/O) semi-solid emulsion by mass spectrometry imaging (MSI). Uniform emulsion droplets were prepared using microchannel emulsification devices with lecithin, stearic acid-binding monoglyceride (St-MAG), and polyglycerol polyricinoleate (PGPR) as emulsifiers. The mass image gives us the localization of phosphatidylcholine (PC) in lecithin, St-MAG, tripalmitin (PPP), medium-chain triglyceride (MCT), and high-melting-point triglyceride tristearin (C18-TAG). PC, St-MAG, and PPP were localized at the interface with the dispersed water droplets. PC and PPP took the same localized position, suggesting an interaction between PC and PPP at the interface. Conversely, PC existed in other regions with St-MAG. MSI revealed multiple target molecules in fat products in a single measurement, and it is expected to reveal fat crystallization at the emulsion interfaces, which will clarify the mechanisms related to the physical properties of high-fat products such as fat spread and butter.

High aspect ratio induced spontaneous generation of monodisperse picolitre droplets for digital PCR

Droplet microfluidics, which involves micrometer-sized emulsion droplets on a microfabricated platform, has been demonstrated as a unique system for many biological and chemical applications. Robust and scalable generation of monodisperse droplets at high throughput is of fundamental importance for droplet microfluidics. Classic designs for droplet generation employ shear fluid dynamics to induce the breakup of droplets in a two-phase flow and the droplet size is sensitive to flow rate fluctuations, often resulting in polydispersity. In this paper, we show spontaneous emulsification by a high aspect ratio (>3.5) rectangular nozzle structure. Due to the confinement and abrupt change of the structure, a Laplace pressure difference is generated between the dispersed and continuous phases, and causes the thread thinning and droplet pinch-off without the need to precisely control external flow conditions. A high-throughput droplet generator was developed by parallelization of a massive number of the basic structures. This device enabled facile and rapid partition of aqueous samples into millions of uniform picolitre droplets in oil. Using this device, on-chip droplet-based digital polymerase chain reaction (PCR) was performed for absolute quantification of rare genes with a wide dynamic range.

Comment on "Robust scalable high throughput production of monodisperse drops" by E. Amstad, M. Chemama, M. Eggersdorfer, L. R. Arriaga, M. P. Brenner and D. A. Weitz, Lab Chip, 2016, 16, 4163

This comment on an article that appeared in Lab on a Chip (Amstad et al., Lab Chip, 2016, 16, 4163-4172) provides information on the performance of microchannel (step) emulsification devices developed by the Nakajima Group.

From single-molecule detection to next-generation sequencing: microfluidic droplets for high-throughput nucleic acid analysis

Droplet-based microfluidic technologies have proved themselves to be of significant utility in the performance of high-throughput chemical and biological experiments. By encapsulating and isolating reagents within femtoliter-nanoliter droplet, millions of (bio) chemical reactions can be processed in a parallel fashion and on ultra-short timescales. Recent applications of such technologies to genetic analysis have suggested significant utility in low-cost, efficient and rapid workflows for DNA amplification, rare mutation detection, antibody screening and next-generation sequencing. To this end, we describe and highlight some of the most interesting recent developments and applications of droplet-based microfluidics in the broad area of nucleic acid analysis. In addition, we also present a cursory description of some of the most essential functional components, which allow the creation of integrated and complex workflows based on flowing streams of droplets.

Collective generation of milliemulsions by step-emulsification

Milliemulsions are produced by microcapillary films based on step-emulsification and the flow behaviors depend on the geometry and capillary number.

Passive and active droplet generation with microfluidics: a review

Precise and effective control of droplet generation is critical for applications of droplet microfluidics ranging from materials synthesis to lab-on-a-chip systems. Methods for droplet generation can be either passive or active, where the former generates droplets without external actuation, and the latter makes use of additional energy input in promoting interfacial instabilities for droplet generation. A unified physical understanding of both passive and active droplet generation is beneficial for effectively developing new techniques meeting various demands arising from applications. Our review of passive approaches focuses on the characteristics and mechanisms of breakup modes of droplet generation occurring in microfluidic cross-flow, co-flow, flow-focusing, and step emulsification configurations. The review of active approaches covers the state-of-the-art techniques employing either external forces from electrical, magnetic and centrifugal fields or methods of modifying intrinsic properties of flows or fluids such as velocity, viscosity, interfacial tension, channel wettability, and fluid density, with a focus on their implementations and actuation mechanisms. Also included in this review is the contrast among different approaches of either passive or active nature.

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.

Formulation and stabilization of nano-/microdispersion systems using naturally occurring edible polyelectrolytes by electrostatic deposition and complexation

This review paper presents an overview of the formulation and functionalization of nano-/microdispersion systems composed of edible materials. We first summarized general aspects on the stability of colloidal systems and the roles of natural polyelectrolytes such as proteins and ionic polysaccharides for the formation and stabilization of colloidal systems. Then we introduced our research topics on (1) stabilization of emulsions by the electrostatic deposition using natural polyelectrolytes and (2) formulation of stable nanodispersion systems by complexation of natural polyelectrolytes. In both cases, the preparation procedures were relatively simple, without high energy input or harmful chemical addition. The properties of the nano-/microdispersion systems, such as particle size, surface charge and dispersion stability were significantly affected by the concerned materials and preparation conditions, including the type and concentration of used natural polyelectrolytes. These dispersion systems would be useful for developing novel foods having high functionality and good stability.

Monodisperse aqueous microspheres encapsulating high concentration of l-ascorbic acid: insights of preparation and stability evaluation from straight-through microchannel emulsification

Stabilization of l-ascorbic acid (l-AA) is a challenging task for food and pharmaceutical industries. The study was conducted to prepare monodisperse aqueous microspheres containing enhanced concentrations of l-AA by using microchannel emulsification (MCE). The asymmetric straight-through microchannel (MC) array used here constitutes 11 × 104 μm microslots connected to a 10 μm circular microholes. 5–30% (w/w) l-AA was added to a Milli-Q water solution containing 2% (w/w) sodium alginate and 1% (w/w) magnesium sulfate, while the continuous phase constitutes 5% (w/w) tetraglycerol condensed ricinoleate in water-saturated decane. Monodisperse aqueous microspheres with average diameters (dav) of 18.7–20.7 μm and coefficients of variation (CVs) below 6% were successfully prepared via MCE regardless of the l-AA concentrations applied. The collected microspheres were physically stable in terms of their dav and CV for >10 days of storage at 40°C. The aqueous microspheres exhibited l-AA encapsulation efficiency exceeding 70% during the storage.

Structured microparticles with tailored properties produced by membrane emulsification

This paper provides an overview of membrane emulsification routes for fabrication of structured microparticles with tailored properties for specific applications. Direct (bottom-up) and premix (top-down) membrane emulsification processes are discussed including operational, formulation and membrane factors that control the droplet size and droplet generation regimes. A special emphasis was put on different methods of controlled shear generation on membrane surface, such as cross flow on the membrane surface, swirl flow, forward and backward flow pulsations in the continuous phase and membrane oscillations and rotations. Droplets produced by membrane emulsification can be used for synthesis of particles with versatile morphology (solid and hollow, matrix and core/shell, spherical and non-spherical, porous and coherent, composite and homogeneous), which can be surface functionalised and coated or loaded with macromolecules, nanoparticles, quantum dots, drugs, phase change materials and high molecular weight gases to achieve controlled/targeted drug release and impart special optical, chemical, electrical, acoustic, thermal and magnetic properties. The template emulsions including metal-in-oil, solid-in-oil-in-water, oil-in-oil, multilayer, and Pickering emulsions can be produced with high encapsulation efficiency of encapsulated materials and narrow size distribution and transformed into structured particles using a variety of solidification processes, such as polymerisation (suspension, mini-emulsion, interfacial and in-situ), ionic gelation, chemical crosslinking, melt solidification, internal phase separation, layer-by-layer electrostatic deposition, particle self-assembly, complex coacervation, spray drying, sol-gel processing, and molecular imprinting. Particles fabricated from droplets produced by membrane emulsification include nanoclusters, colloidosomes, carbon aerogel particles, nanoshells, polymeric (molecularly imprinted, hypercrosslinked, Janus and core/shell) particles, solder metal powders and inorganic particles. Membrane emulsification devices operate under constant temperature due to low shear rates on the membrane surface, which range from (1-10)×10(3) s(-1) in a direct process to (1-10)×10(4) s(-1) in a premix process.

Formulation characteristics of triacylglycerol oil-in-water emulsions loaded with ergocalciferol using microchannel emulsification

Food grade monodisperse O/W emulsions encapsulating ergocalciferol have been formulated using microchannel emulsification. The O/W emulsion droplets have an encapsulation efficiency of over 75% within the evaluated storage period.

Advances in membrane emulsification. Part A: recent developments in processing aspects and microstructural design approaches

Modern emulsion processing technology is strongly influenced by the market demands for products that are microstructure-driven and possess precisely controlled properties. Novel cost-effective processing techniques, such as membrane emulsification, have been explored and customised in the search for better control over the microstructure, and subsequently the quality of the final product. Part A of this review reports on the state of the art in membrane emulsification techniques, focusing on novel membrane materials and proof of concept experimental set-ups. Engineering advantages and limitations of a range of membrane techniques are critically discussed and linked to a variety of simple and complex structures (e.g. foams, particulates, liposomes etc.) produced specifically using those techniques.

Industrial lab-on-a-chip: design, applications and scale-up for drug discovery and delivery

Microfluidics is an emerging and promising interdisciplinary technology which offers powerful platforms for precise production of novel functional materials (e.g., emulsion droplets, microcapsules, and nanoparticles as drug delivery vehicles- and drug molecules) as well as high-throughput analyses (e.g., bioassays, detection, and diagnostics). In particular, multiphase microfluidics is a rapidly growing technology and has beneficial applications in various fields including biomedicals, chemicals, and foods. In this review, we first describe the fundamentals and latest developments in multiphase microfluidics for producing biocompatible materials that are precisely controlled in size, shape, internal morphology and composition. We next describe some microfluidic applications that synthesize drug molecules, handle biological substances and biological units, and imitate biological organs. We also highlight and discuss design, applications and scale up of droplet- and flow-based microfluidic devices used for drug discovery and delivery.

Bubble production mechanism in a microfluidic foam generator

We present the design and characterization of a microfluidic bubble generator that has the potential of producing monodisperse bubbles in 256 production channels that can operate in parallel. For a single production channel we demonstrate a production rate of up to 4 kHz with a coefficient of variation of less than 1%. We observe a two-stage bubble production mechanism: initially the gas spreads onto a shallow terrace, and then overflows into a larger foam collection channel; pinning of the liquid-gas meniscus is observed at the terrace edge, the result being an asymmetric pinch-off. A semiempirical physical model predicts the scaling of bubble size with fluid viscosity and gas pressure from measurements of the pinned meniscus width.

Droplet based microfluidics

Droplet based microfluidics is a rapidly growing interdisciplinary field of research combining soft matter physics, biochemistry and microsystems engineering. Its applications range from fast analytical systems or the synthesis of advanced materials to protein crystallization and biological assays for living cells. Precise control of droplet volumes and reliable manipulation of individual droplets such as coalescence, mixing of their contents, and sorting in combination with fast analysis tools allow us to perform chemical reactions inside the droplets under defined conditions. In this paper, we will review available drop generation and manipulation techniques. The main focus of this review is not to be comprehensive and explain all techniques in great detail but to identify and shed light on similarities and underlying physical principles. Since geometry and wetting properties of the microfluidic channels are crucial factors for droplet generation, we also briefly describe typical device fabrication methods in droplet based microfluidics. Examples of applications and reaction schemes which rely on the discussed manipulation techniques are also presented, such as the fabrication of special materials and biophysical experiments.

Producing monodisperse drug-loaded polymer microspheres via cross-flow membrane emulsification: the effects of polymers and surfactants

Cross-flow membrane emulsification (XME) is a method for producing highly uniform droplets by forcing a fluid through a small orifice into a transverse flow of a second, immiscible fluid. We investigate the feasibility of using XME to produce monodisperse solid microspheres made of a hydrolyzable polymer and a hydrophobic drug, a model system for depot drug delivery applications. This entails the emulsification of a drug and polymer-loaded volatile solvent into water followed by evaporation of the solvent. We use a unique side-view visualization technique to observe the details of emulsion droplet production, providing direct information regarding droplet size, dripping frequency, wetting of the membrane surface by the two phases, neck thinning during droplet break off, and droplet deformation before and after break off. To probe the effects that dissolved polymers, surfactants, and dynamic interfacial tension may have on droplet production, we compare our results to a polymer and surfactant-free fluid system with closely matched physical properties. Comparing the two systems, we find little difference in the variation of particle size as a function of continuous phase flow rate. In contrast, at low dripping frequencies, dynamic interfacial tension causes the particle size to vary significantly with drip frequency, which is not seen in simple fluids. No effects due to shear thinning or fluid elasticity are detected. Overall, we find no significant impediments to the application of XME to forming highly uniform drug-loaded microspheres.

Continuous flow structuring of anisotropic biopolymer particles

We review concepts and provide examples for the controlled structuring of biopolymer particles in hydrodynamic flow fields. The structuring concepts are grouped by the physical mechanisms governing drop deformation and shaping: (i) capillary structuring, (ii) shear and elongational structuring and (iii) confined flow methods. Non-spherical drops can be permanently structured if a solidification process, such as gelation or glass formation in the bulk or at the interface, is superimposed to the flow field. The physical and engineering properties of these processes critically depend on an elaborate balance between capillary phenomena, rheology, gel or glass formation kinetics, and bulk heat, mass and momentum transfer in multiphase fluids. This overview is motivated by the potential of non-spherical suspension particles, in particular those formed from 'natural' and 'sustainable' biopolymers, as rheology modifiers in food materials, consumer products, cosmetics or pharmaceuticals.

A geometric model for the dynamics of microchannel emulsification

Microchannel emulsification is an interfacial tension driven method to produce monodisperse microdroplets, or microspheres. In this paper we introduce a model for describing the dynamics of microchannel emulsification based on simple time dependent geometric shape analysis. The model is based on mechanistic principles that simultaneously predicts both process and microchannel geometry effects. The model contains no adjustable (fit) parameters and is thus fully predictive for oil in water emulsification. The model is easy to use and does not require extensive computational time and/or memory. The model was validated by comparison with the experimental results published by Sugiura and co-workers and we found excellent agreement. It was found that the droplet size of oil in water emulsions could be fully predicted using only two dimensionless numbers, an adapted capillary number that also comprises effects of terrace width and height, and the ratio of terrace length over terrace height. Based on these findings, a dimensionless design map could be constructed for a wide range of process conditions and microchannel dimensions.

Flow-field dynamics during droplet formation by dripping in hydrodynamic-focusing microfluidics

Using microscopic particle image velocimetry, we examine the flow field around an oil droplet as it is formed by hydrodynamic focusing in an aqueous solution using a pressure-driven cross-channel microfluidic device. By detecting the temporal dependence of the instantaneous flow fields of the continuous phase in the dripping regime, we show that shear is not the primary mechanism that initiates droplet formation in our low flow rate and moderate capillary number experimental conditions. Instead, the advancing finger of oil partially and temporarily plugs the outlet channel, creating a pressure difference that builds up and is released when water from the side channels pushes the tip of the finger into the outlet channel, thereby facilitating the birth of the droplet by interfacial pinch-off that is primarily initiated by an extensional flow.