Solidification or crystallization of phase change emulsion in the form of fine emulsion drops in a direct contact coolant at temperatures below their freezing point was studied. This work is mainly focused on the size and shape of the generated particles from phase change emulsified fats. Size of the particles is the major or key factor being considered during their formation, however, other factors that govern the particle size and shape were also observed. The operating parameters of the process were optimized in order to obtain particles of smaller size ranges in the window of current operating conditions. The crystallization of complex emulsion matrices is very difficult to control in the bulk at desired requirement. Hence, the emulsion drop to particle formation has advantage in comparison with the bulk solidification or crystallization. The main objective of this work is to achieve spherical emulsion particles in a direct contact cooling system. Parameters like: stability, characterization, viscosity, and the effect of different energy inputs were examined. Moreover, the effects of the capillary size, interfacial tension, temperature of the emulsion on the particle size were also monitored. (C) 2015 The Chemical Industry and Engineering Society of China, and Chemical Industry Press. All rights reserved.