Drop shaping, i.e., flow-induced deformation and fixation by gel formation, was studied under dynamic conditions in a fast continuous process for a water-in-oil system. The system consisted of sunflower oil with different surfactant concentrations (0.1-2% Admul Wol) and a 1.5% kappa-carrageenan solution with different Na+ and K+ concentrations. The continuous phase flowed in a 10-mm-wide straight channel into which the dispersed phase was injected via a thin needle. A subsequent shaping channel with a width of 1 or 2 mm deformed the drops. Gel formation was induced by a temperature gradient between the continuous and dispersed phase. Drop sizes in the range 220-roughly 1000 mum were produced at the needle tip by varying the ratio between the oil and carrageenan flow rate. A diffusion zone before the narrow channel allowed the surfactant to adsorb at the interface. In the elongation flow at the entrance of the shaping geometry, drops underwent initial elongation. In the narrow channel, the drops developed a parabolic shape within a residence time of 0.03-0.15 s. Choosing the correct parameter combinations made it possible to fix the deformation by gel formation within this time period. Shaped drops were shown to be functional. At a concentration of 25% in an emulsion, they increased the viscosity by about 15-20% compared to spherical drops even though 45% of the shaped drops had an aspect ratio of less than 1.2. (C) 2003 Elsevier Inc. All rights reserved.