Optimizing continuous emulsification with 3D printing

Abstract

Multiphase processes are important in a wide range of industries including foods, pharmaceuticals, and consumer packaged goods. Improvement of these operations is challenging because of the complex hydrodynamics of the processing unit. We approached intensification of emulsification operations using continuous processing and hydrodynamic optimization with computer aided design and three dimensional printing (3dP) of fixed bed (FB) unit operations. We built and tested the emulsification capability of 3dPFB to establish key relationships among digital design variables, such as surface to volume ratio of the 3dPFB, 3.3≤s×10−4≤9.0m−1, and process performance metrics, such as drop size distribution (23.1±5.7<DSD<125.7±33.2μm). We showed that the emulsification performance can be designed a priori and demonstrated gradient 3dPFB design and complex emulsification to further establish the digital basis of design-property relationships and capabilities of 3dPFB in multiphase unit operations.