Liposomes have numerous applications in the (bio)pharmaceutical industries as agents in the synthesis of new biomaterials for use in areas including gene delivery. There is currently a need to establish efficient scaleable methods for the manufacture of liposomes, and in the present paper we describe the operation of a new high-velocity jet homogenizer for downsizing of multilamellar large vesicles to produce small unilamellar vesicles (SUV). Measurements of size distribution of SUVs are presented and compared with mathematical simulations based on the solution of a population balance equation combined with computational-fluid-dynamics analysis of flow in the homogenizer. Anionic SUVs are produced by the new method and incubated with poly-L-lysine (PLL)-condensed plasmid DNA (pDNA) to generate complexes under different physico-chemical conditions. The colloidal properties of the resulting complexes, including their size and charge, are measured using a Zetasizer and the encapsulation efficiency is obtained experimentally using a Pico Green assay. The results show that between 85 and 95% of the PLL-pDNA condensed plasmids were encapsulated by the liposomes, the smaller liposomes being more effective in encapsulating the complexes.