In manufacturing and applying emulsions it is often necessary to predict or control their flow and adjust their viscosity. A new method is presented for including the effect of the droplet size distribution on the rheological behaviour of dense oil-in-water emulsions of noncolloidal droplets. The method is based on extension of the advanced model for the relative viscosity of the concentrated monodisperse emulsion to account for polydispersity effects. The model includes effects of volume fraction of the dispersed phase, droplet size distribution, interfacial tension and shear rate on the relative emulsion viscosity. The model has universal character and can be combined with the population balance equation and CFD. Examples of modelling are presented for laminar and turbulent flows of dense emulsions. In the case of laminar flow the Couette flow and the Taylor-Couette flow are considered. In the case of turbulent flow it is shown how dispersion of droplets in the high-shear rotor-stator mixer affects the flow pattern and rheology of the emulsion product. (C) 2015 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.