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The steady-state shear viscosity η(γ̇)\eta (\dot{\gamma }) is required in controlling processing parameters for the extrusion processing of polymer melts. A new method, the so-called ramp test, is investigated in this study to obtain the steady-state shear viscosity with a closed cavity rheometer (CCR). To verify the method and the accuracy of the CCR data, three commercial polyolefin polymers, a low-density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), and a polybutadiene (PBD), were used as model systems. Measurements of the magnitude of the complex viscosity ∣η⁎(ω)∣| {\eta }^{\ast }(\omega )| were compared with the steady-state shear viscosity data obtained by capillary rheometer and CCR. Further, time–temperature superposition master curves of the magnitude of the complex viscosity and steady-state shear viscosity obtained by CCR were developed for LLDPE and PBD. The influence of the cavity sealing on the instrument’s accuracy to obtain the steady-state shear viscosity was investigated using the finite element method simulations. Thus, it was shown that the ramp test performed by CCR is a practical method to determine reliable and reproducible data of the steady-state shear viscosity within a wide range of temperatures (T = 50–180°C) for low and high viscous materials (∣η⁎(ω)∣| {\eta }^{\ast }(\omega )| = 1.6–480 kPa s, M w = 144–375 kg mol−1).

Spray drying of oil-in-water emulsions is a widespread encapsulation technique. The oil droplet size (ODS) significantly impacts encapsulation efficiency and other powder properties. The ODS is commonly set to a specific value during homogenization, assuming that it remains unchanged throughout the process, which is often inaccurate. This study investigated the impact of atomizer geometry and nozzle dimensions on oil droplet breakup during atomization using pressure-swirl atomizers. Subject of the investigation were nozzles that differ in the way the liquid is set in motion, as well as different inlet port and outlet orifice dimensions. The results indicate that nozzle inlet port area may have a significant impact on oil droplet breakup, with x90,3 values of the oil droplet size distribution decreasing from 5.29 to 2.30 µm with a decrease of the inlet area from 2.0 to 0.6 mm. Good scalability of the findings from pilot to industrial-scale was shown using larger nozzles. A simplified theoretical model, aiming to predict the ODS as a function of calculated shear rates, showed reasonable agreement to the experimental data for different atomization pressures with coefficients of determination of up to 0.99. However, it was not able to predict the impact of different nozzle dimensions, most likely due to changes in flow characteristics. These results suggest that the stress history of the oil droplets might have a larger influence than expected. Further studies will need to consider other zones of high stress in addition to the outlet orifice. [ABSTRACT FROM AUTHOR]