Despite the wide range of industrial applications of structured emulsions, current approaches toward process design and scale-up are commonly based on trial-and-error experimentation. As this design approach is foreseen to deliver most likely suboptimal process solutions, we propose in this contribution a model-based approach as the way forward to designing manufacturing processes of structured emulsions. In this context, process modelling and simulation techniques are applied to predict production rates and equipment sizing. Moreover, sensitivity analysis of the process model provides insight about potential bottlenecks in the process. (C) 2010 Elsevier Ltd. All rights reserved.