The key to creating a stable emulsion is obtaining the finest possible droplet size. The more shear energy introduced into the mix, the smaller the suspended droplets will become, creating a fine stable emulsion.

The high shear rotor/stator design of the Silverson mixer is ideally suited to this application and can easily achieve emulsions with a droplet size of 2 to 5 microns. Finer emulsions down to 0.5 microns can be obtained, depending on the formulation. In many cases, this can eliminate the need for high pressure homogenisers.

Where a high pressure homogeniser must be used, premixing the emulsion with a Silverson In-Line mixer prior to the high pressure homogeniser will allow the product to pass through at a much higher rate, since homogenisers work more efficiently when fed with a premix of a uniform and fine droplet size.