Emulsification is a critical unit operation in many chemical, pharmaceutical, and specialty manufacturing
processes, where product performance and stability are strongly influenced by droplet size distribution. While pilot-
scale trials can demonstrate technical feasibility, scaling up to higher throughputs often introduces challenges such
as increased droplet coalescence, non-uniform energy dissipation, and loss of product consistency.
In-line Rotor–Stator Devices (RSDs) are widely used for continuous emulsification due to their high shear
capability in compact designs; however, maintaining emulsification efficiency during scale-up requires careful
evaluation of equipment design and operating conditions.
This case study presents the application of VisiMix RSDE for scaling up an oil-in-water emulsification process
using a multi-stage in-line rotor–stator system. By combining pilot-scale validation with mathematical
modeling, VisiMix RSDE was used to predict droplet size distribution, evaluate coalescence effects, and optimize
a three-stage RSD configuration capable of higher production rates without compromising emulsion quality. The
study highlights how simulation-driven design reduces reliance on trial-and-error experimentation and enables
confident, low-risk scale-up of continuous emulsification processes.