Continuous production of dilute to dense food grade emulsions via vapor condensation on films

The EVC-F process produced submicron droplets (100 to 800 nm) with tunable ϕ up to about 25%, surpassing previous EVC systems that produced less than 1%. PGPR yielded highly stable emulsions with monomodal, narrow droplet size distributions and near-Newtonian like rheology, whereas lecithin produced larger and more polydisperse droplets. Mixed systems exhibited composition dependent stability, with PGPR rich blends remaining stable for more than 30 days. The improved stability of EVC-F emulsions relative to ultrasonication suggests that condensation-driven interfacial nucleation mitigates coalescence and dispersed phase loss typically observed under shear-dominated, non-isothermal conditions. These results establish EVC-F as a thermally gentle, energy-efficient, and scalable route for producing dilute to dense food-grade emulsions relevant to soft-matter, colloidal, and interfacial science.