Three-factor response surface optimization of nano-emulsion formation using a microfluidizer.

Emulsification of sunflower oil in water by microfluidization was studied. Response surface methodology (RSM) and the central composite design (CCD) were applied to determine the effects of certain process parameters on performance of the apparatus for optimization of nano-emulsion fabrication. Influence of pressure, oil content and number of passes on the disruption of emulsions was studied. Quadratic multiple regression models were chosen for two available responses, namely Sauter mean diameter (SMD) and Polydispersity index (PdI). Analysis of variance (ANOVA) showed a high coefficient of determination (R(2)) value for both responses, confirming adjustment of the models with experimental data. The SMD and the PdI decreased as the pressure of emulsification increased from 408 to 762.3 bar for the oil content of 5 vol% and from 408 to 854.4 bar for the oil content of 13 vol%, and thereafter, increasing the pressure up to 952 bar led to increasing the both responses. The results implied that laminar elongational flow is the alternative disruption mechanism in addition to inertia in turbulence flow, especially at low treatment pressures. Both of responses improved with increase in number of passes from 2 to 4 cycles. The oil content depicted low effect on responses; however, interaction of this parameter with other regressors pointed remarkable impact. Also, the effect of pressure on Kolmogorov micro-scale was studied. The results implied that Kolmogorov equation did not take into account the over-processing and was applicable only for disruption of droplets in the inertial turbulent flow.