This research studied the effect of kappa-carrageenan concentration and emulsifier mixture of soybean lecithin (LEC) and/or polyglycerol polyricinoleate (PGPR) on the physical properties of water-in-cocoa butter emulsions. Emulsions were prepared using bench scale margarine line process, consisting of a scraped surface heat exchanger and a pin stirrer. Results show that droplet size increases as the concentration of kappa-carrageenan and/or LEC increases. Emulsions crystallise mainly in form V (beta(2)), however when the concentration of kappa-carrageenan increases to 1.5 wt% less stable polymorphic forms (II) were also observed. The rheological properties of the emulsions at 40 degrees C were mainly controlled by the concentration of LEC which causes droplets to flocculate and as consequence viscosity increases. Finally, behaviour under large deformation showed that the presence of water droplets weakens the emulsions structure, due to the reduction in the density of the cocoa butter matrix bearing the load. (C) 2014 Elsevier Ltd. All rights reserved.