Rotor-stator and disc systems for emulsification processes

Emulsions now find a wide range of applications in industry and daily life. In the pharmaceutical industry lipophilic active ingredients as well as many nutritional products such as vitamins are often formulated in the dispersed phase of oil-in-water emulsions. Emulsions can be produced with different mechanical emulsification techniques. In the following review, the process of rotor-stator systems and disc systems are compared to other popular mechanical emulsification systems. On the basis of experimental results from the authors' laboratory, a discontinuous gear-rim dispersing system, discontinuous disc system, and a continuous high pressure system are compared with regard to their attainable mean droplet diameter and drop size distribution in an oil-in-water emulsion. It can be shown that dissolver discs with a very simple geometry attain very small mean droplet diameters and a very narrow droplet size distribution, comparable to the emulsions obtained with established rotor-stator systems such as gear-rim dispersers.