Exploring the stability of single emulsion created by microfluidics and its use in the production of core–shell microparticles

This study introduces an innovative method aimed at achieving exceptional stability in emulsions. The primary focus is on re-emulsifying precisely controlled and uniform initial single emulsions, generated by microfluidic devices, to produce single-core double emulsions and core–shell microparticles. Departing from traditional approaches, our method employs a unique combination of advanced Two-level fractional factorial design and numerical simulation. These tools are utilized to discern and optimize critical parameters necessary for the formation of highly monodispersed stable single emulsions and their subsequent transformation into double emulsions. Correlations are established to estimate the size and stability of the primary single emulsion based on immiscible phase flow rate ratio and surfactant concentration. These correlations provide a comprehensive understanding that facilitates the intentional development of desired water-in-oil emulsions. The proposed microfluidic paradigm shows promise for the controlled and efficient production of single-core double emulsions, with broad applications in Pharmaceuticals, Food, and Cosmetics.