The work concerns numerical simulations of a cone mill used for emulsion preparation. Hydrodynamics, power consumption and population balance are investigated for various operating conditions at high phase volume emulsions and for different rheologies. Cone mills are usually simplified as a simple gap between rotor and stator but by increasing the complexity of the geometry till it represents the commercial device identifies a wealth of additional features such as recirculation zones above (which enhance breakage) and below (which allow for coalescence) the rotor-stator gap. Two separate sets of population balance modelling constants are required to capture all the experiment results – even with the most complex geometries. Some suggestions are made for improvements and further studies will consider other rotor-stator devices.