Uniform droplets of soybean oil, MCT (medium-chain fatty acid triglyceride) oil and n-tetradecane with a mean diameter of 26-29 mu m have been generated using a silicon 24 x 24 mm microchip consisting of 23,489 asymmetric microchannels fabricated by photolitography and deep-reactive ion etching. Each microchannel consisted of a circular 10-mu m diameter straight hole with a length of 70 mu m and a 50 x 10 mu m rectangular microslot with a depth of 30 mu m. At the constant oil flux of 10 L m(-2) h(-1), the percent of active channels increased with increasing the oil viscosity and ranged from 4% for n-tetradecane to 48% for soybean oil. The size distribution span for SDS (sodium dodecyl sulphate)- and Tween 20 (polyoxyethylene (20) sorbitan monolaurate)-stabilized soybean and MCT oil droplets was 0.21-022. The ability of asymmetric microchannels to generate monodisperse soybean oil droplets at the very low SDS concentration of 0.01 wt.% has been demonstrated. At the SDS concentration below the CMC, the generated droplets tend to attach to the plate surface, whereas at the higher SDS concentration they detach from the plate as soon as they are formed. The agreement between the experimental and CFD (Computational Fluid Dynamics) simulation results was excellent for soybean oil and the poorest for n-tetradecane. (C) 2007 Elsevier B.V. All rights reserved.