An innovative emulsification technology that produces modern emulsions at a reasonable cost has been demonstrated. This process is useful for producing conventional emulsions, and so-called "surfactant free" emulsions, which are stabilized by particles and/or amphipathic polymers. Such emulsions present significant formulation and processing challenges because conventional emulsification techniques rely upon shear force to break up the droplets formed by the discontinuous phase and to transport the emulsifier to the interface. Microchannel emulsification technology is unlike traditional methods that use high-shear forces to form small droplets. This technology, which consists of intervening microchannels with apertured substrates, adds the discontinuous to the continuous phase, one droplet at a time, and provides better control than conventional methods. The droplet size distribution is controlled by adjusting critical process parameters (mixing energy, mixing time), and precise heating and/or cooling.