Solvent-free extrusion emulsification (SFEE) is a complex process using twin-screw extrusion to prepare solid-liquid dispersions of high viscosity polymers and has received little study to date on its inherent mechanisms. To gain rheological insights into the earliest stage of SFEE as the interfacial boundary between water and polymer grows, prior to phase inversion, an inline orifice-plate type viscometer is introduced to monitor transient behavior over a wide range of viscosities. The presented work examines rheological changes of a polyester-water system produced by varying two factors thought to significantly control the final state of the dispersion, specifically polar group contributions to surface energy and viscosity. A processing modifier was combined with the polyester to study the influence of these two factors. The inline viscometer revealed an abrupt transition in viscosity occurred with the developed state of water dispersion, confirming observations of a prior batch study. Analysis of the rheological response indicated that a higher polar surface energy contribution had the greatest influence on the state of this transition, and that a steeper transition was related to greater incorporation of water within the polyester matrix. POLYM. ENG. SCI., 2017. (c) 2017 Society of Plastics Engineers