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The droplet breakups in an orifice jet mixer are studied to gain a deeper understanding of the breakup mechanism and establish breakup models used as population balance model source terms for accurate predictions. The breakup process and details are captured in situ using a high‐speed photomicrography system. Experiments are performed with different levels of pressure drop and mother droplet size. A complete breakup process consists of several different sub‐breakup events, hence the cascade breakup definition is adopted to determine statistical results. High breakup frequency is achieved under high pressure drop and small mother droplet size. The average number of daughter droplets is 102–105 and is positively correlated with the pressure drop and mother droplet size. The daughter droplet size distribution has a tailing phenomenon and is mainly affected by the pressure drop. New breakup models based on the above features are established and predict well with the experimental results. [ABSTRACT FROM AUTHOR]