<p>In this paper, an optimal vibrating ultrasonic horn for emulsion homogenization is proposed and fabricated using the equilibrium optimization algorithm. The use of various ultrasonic equipment, such horns, in a range of industrial processes is growing and developing. A horn's design should take into account several important factors, including as the horn's length, cavitation spread across its length, amplitude of vibration, length-to-diameter ratio, frequency separation from other modes, and enhanced acoustic energy transfer area. The optimized horn's design process is carried out after taking these crucial factors into account and applying the equilibrium optimization algorithm, which is carried out by MATLAB and ABAQUS software coupled. The horn's amplification factor is used to construct the objective function, and the remaining features are defined as design constraints. According to the simulation results, the natural frequency is 15% higher than the goal frequency, and there should be a reasonable 2.5 kHz gap in frequency between the prior and next modes. The suggested horn has an amplification factor of 15, as indicated by the barbell portion of the horn. The vibration's frequency and amplitude were measured, and the horn was constructed according to plan. The experimental results were so close to the simulation ones. In addition, the results of the qualitative evaluation in emulsion homogenization, creaming index, emulsion activity index, and emulsion stability index showed that the emulsion obtained from the proposed horn during four minutes of sonication has the lowest percentage of creaming index and the highest proportion of both emulsions activity and emulsions stability index.</p>