Highly concentrated bitumen-in-water emulsions were produced with static mixers in continuous mode. The effect of the following process parameters on the average droplet size was studied: emulsion flowrate, static mixers configuration, and surfactant concentration as well as bitumen hardness, concentration, and temperature. Several static mixer configurations were investigated consisting of combinations of SMX (Sulzer Chemtech Ltd.) and helical elements with empty sections. The drop size results revealed that the mean droplet size could be scaled with the energy or the power draw depending on the static mixer configuration. Moreover, it was shown that the energy draw could capture the effect of emulsion flowrate and bitumen concentration on the mean droplet size, whereas the power draw (or the specific power) captured the effect of the emulsion flowrate and bitumen temperature. It was also demonstrated that the specific energy, or pressure drop, was minimized when SMX mixers were inserted after helical mixers.