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<p>The growing imperative for energy efficiency and sustainable development has catalyzed widespread interest in green manufacturing practices within the food industry. Traditional high-energy emulsification methods rely on intensive mechanical forces, which entail high operational costs and align poorly with sustainability goals. In contrast, low-energy emulsification techniques, which better align with sustainable production needs, are increasingly attracting interest and investment. However, the industrial scalability of these technologies remains hindered by challenges regarding formulation stability, equipment capacity, production efficiency, and cost-effectiveness. This review provides a comprehensive overview of the developments of low-energy emulsification techniques, including self-emulsification, membrane emulsification, and microfluidic emulsification. It elucidates the updated droplet formation mechanisms inherent to each method, systematically compares their industrial parameters such as throughput and energy efficiency, and critically evaluates their translational relevance to food emulsions and food-grade delivery systems. Furthermore, recent advancements in machine learning offer promising avenues to overcome existing bottlenecks in formulation optimization, equipment design, and process upscaling. These advancements are anticipated to facilitate the translation of low-energy emulsification technologies into food production, guiding the industry toward more sustainable methods.</p> Graphical Abstract <p></p>

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Low-energy Emulsification Approaches: Mechanisms, Device Advances, and Translation to Food Systems

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Yikun Liu,
  • Ling Guo,
  • Xing Chen,
  • Yuqing Dong,
  • Liqiang Zou,
  • Wei Liu

摘要

The growing imperative for energy efficiency and sustainable development has catalyzed widespread interest in green manufacturing practices within the food industry. Traditional high-energy emulsification methods rely on intensive mechanical forces, which entail high operational costs and align poorly with sustainability goals. In contrast, low-energy emulsification techniques, which better align with sustainable production needs, are increasingly attracting interest and investment. However, the industrial scalability of these technologies remains hindered by challenges regarding formulation stability, equipment capacity, production efficiency, and cost-effectiveness. This review provides a comprehensive overview of the developments of low-energy emulsification techniques, including self-emulsification, membrane emulsification, and microfluidic emulsification. It elucidates the updated droplet formation mechanisms inherent to each method, systematically compares their industrial parameters such as throughput and energy efficiency, and critically evaluates their translational relevance to food emulsions and food-grade delivery systems. Furthermore, recent advancements in machine learning offer promising avenues to overcome existing bottlenecks in formulation optimization, equipment design, and process upscaling. These advancements are anticipated to facilitate the translation of low-energy emulsification technologies into food production, guiding the industry toward more sustainable methods.

Graphical Abstract