A Microfluidic Approach to Investigate the Contact Force Needed for Successful Contact-Mediated Nucleation

Emulsions with crystalline dispersed phase fractions are becoming increasingly important in the pharmaceutical, chemical, and life science industries. They can be produced by using two-stage melt emulsification processes. The completeness of the crystallization step is of particular importance as it influences the properties, quality, and shelf life of the products. Subcooled, liquid droplets in agitated vessels may contact an already crystallized particle, leading to so-called contact-mediated nucleation (CMN). Energetically, CMN is a more favorable mechanism than spontaneous nucleation. The CMN happens regularly because melt emulsions are stirred during production and storage. It is assumed that three main factors influence the efficiency of CNM, those being collision frequency, contact time, and contact force. Not all contacts lead to successful nucleation of the liquid droplet, therefore, we used microfluidic experiments with inline measurements of the differential pressure to investigate the minimum contact force needed for successful nucleation. Numerical simulations were performed to support the experimental data obtained. We were able to show that the minimum contact force needed for CMN increases with increasing surfactant concentration in the aqueous phase.