The aim of this work was to understand the physical characteristics of cocoa butter water in oil emulsions made using a process typically used for margarine production (a scraped surface heat exchanger and pin stirrer). Processing parameters were manipulated, and the effect of aqueous phase volume, polyglycerol polyricinoleate (PGPR) concentration, and the addition of a hydrocolloid to the aqueous phase were investigated. This process allowed small droplets to be formed (3-5 mu m). Tempering could also be mimicked, with the temperature of the units affecting the polymorphic form of cocoa butter produced. Sintered crystalline shells were observed at the oil/water droplet interface, acting as Pickering particles. This work highlights the potential for the use of cocoa butter emulsions to give fat reduction in chocolate, using a one step process to achieve emulsification and to mimic tempering. (c) 2012 Elsevier Ltd. All rights reserved.