A method for optimizing a Hegman rating of a diluted emulsion comprising: (a) feeding a molten polymer resin into a melt kneader; (b) feeding an initial water stream into the melt kneader; (c) feeding a basic aqueous solution and/or a dispersing agent into the melt kneader to form a concentrated emulsion, wherein the concentrated emulsion comprises from greater than 60 wt% polymer resin solids; (d) feeding the concentrated emulsion into a dilution mixer wherein water is continuously or in a single or multi-stage manner added to the concentrated emulsion to dilute the concentrated emulsion to form an diluted emulsion, wherein the diluted emulsion comprises equal to or less than 70 wt% polymer resin solids; (e) measuring a first Hegman rating of a first sample of the diluted emulsion; (f) determining if the first Hegman rating of the first sample is acceptable for an intended end use application; (g) if the first Hegman rating of the first sample is not acceptable, adjusting the shear work in the dilution mixer, wherein the adjusting the shear work may comprise raising or lowering the shear work; (h) measuring a second Hegman rating of a second sample of the diluted emulsion; (i) determining if the second Hegman rating of the second sample is acceptable for the intended end use application; (j) if the second Hegman rating of the second sample is not acceptable, adjusting the temperature of the concentrated and/or diluted emulsion; (k) measuring a third Hegman rating of a third sample of the diluted emulsion; (l) determining if the third Hegman rating of the third sample is acceptable for the intended end use application; and (m) if the third Hegman rating of the third sample is not acceptable, conducting one or more steps selected from the group consisting of (i) if not earlier added, adding a basic aqueous solution and/or surfactant solution; (ii) adding one or more other additives; and (iii) adjusting the amount of any additive, basic solution or surfactant solution; (n) measuring a fourth Hegman rating of a fourth sample of the diluted emulsion; (o) determining if the fourth Hegman rating of the third sample is acceptable for the intended end use application; (p) if the fourth Hegman rating is not acceptable, repeating any one or more of steps (g), (j) and (m); (q) if the first, second, third or fourth Hegman rating is acceptable, collecting the diluted emulsion. (a) feeding a molten polymer resin into a melt kneader; (b) feeding an initial water stream into the melt kneader; (c) feeding a basic aqueous solution and/or a dispersing agent into the melt kneader to form a concentrated emulsion, wherein the concentrated emulsion comprises from greater than 60 wt% polymer resin solids; (d) feeding the concentrated emulsion into a dilution mixer wherein water is continuously or in a single or multi-stage manner added to the concentrated emulsion to dilute the concentrated emulsion to form an diluted emulsion, wherein the diluted emulsion comprises equal to or less than 70 wt% polymer resin solids; (e) measuring a first Hegman rating of a first sample of the diluted emulsion; (f) determining if the first Hegman rating of the first sample is acceptable for an intended end use application; (g) if the first Hegman rating of the first sample is not acceptable, adjusting the shear work in the dilution mixer, wherein the adjusting the shear work may comprise raising or lowering the shear work; (h) measuring a second Hegman rating of a second sample of the diluted emulsion; (i) determining if the second Hegman rating of the second sample is acceptable for the intended end use application; (j) if the second Hegman rating of the second sample is not acceptable, adjusting the temperature of the concentrated and/or diluted emulsion; (k) measuring a third Hegman rating of a third sample of the diluted emulsion; (l) determining if the third Hegman rating of the third sample is acceptable for the intended end use application; and (m) if the third Hegman rating of the third sample is not acceptable, conducting one or more steps selected from the group consisting of (i) if not earlier added, adding a basic aqueous solution and/or surfactant solution; (ii) adding one or more other additives; and (iii) adjusting the amount of any additive, basic solution or surfactant solution; (n) measuring a fourth Hegman rating of a fourth sample of the diluted emulsion; (o) determining if the fourth Hegman rating of the third sample is acceptable for the intended end use application; (p) if the fourth Hegman rating is not acceptable, repeating any one or more of steps (g), (j) and (m); (q) if the first, second, third or fourth Hegman rating is acceptable, collecting the diluted emulsion.