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Formulation Technology Dr. Murat Mertoglu Denmark, September 6, 2012
Outline
Definition of formulation
Formulation types
Requirement of formulations
Delivery of actives to target vs. formulation
Exercise: lets chose a formulation type
Future trends: more sustainable formulations
Summary
2 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
What Does the Term “Formulation” Mean?
Definition: Formulation is the process of converting
an active ingredient (or technical-
material) into an applicable product.
Cheese
Cake
Flat
Cake
You cannot get a good product only by using good active ingredients, formulation also plays a key role in the success of a product on the field!
3 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Formulation Technology
Codes of Plant Protection Products
Code Description
EC Emulsifiable concentrate
SL Soluble concentrate
DC Dispersible concentrate
SC Suspension concentrate
SE Suspoemulsion
FS Flowable concentrate for seed treatment
OD Dispersion in oil
EW Emulsion, oil in water
ME Microemulsion
CS Capsule suspension
WG Water dispersible granule
WP Wettable powder
International coding
http://www.croplife.org
Search for:
„Technical Monograph No2“
63 codes
(+ 29 abandoned)
4 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Choice of Formulation Type
biological efficacy
– systemic, and/or contact
intrinsic physical and chemical properties
– liquid/ solid, melting point, solubility, stability, volatile, etc....)
type application (herbicide, insecticide, fungicide)
type of crop (cereals, specialty crop…)
regulatory
– eye tox, tank mix additive, smell, drift
packaging ( 5 lt, 10, 50 lt, 1000 lt)
plays a key role in the field the performance and the market success
5 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Simple Classification
6 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Simple Classification
7 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Liquid Formulation
dilute
in water
X 400
EC (ME) emulsion
DC a.i. particles
< 150 nm
SL a.i.
dissolved
8 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Liquid Formulation
a.i.+ solvent
solvent a.i. crystal
water
dilute
in water
X 400
9 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Typical additives for continuous phase water
SC, SE, EW
─ dispersing agent,
─ antifreeze,
─ thickener,
─ bactericide,
─ antifoaming agent
─emulsifier
─solvent,
─adjuvants (to improve spreading,
uptake, retention),
─crystallization inhibitors,
─stabilizers (buffer, antioxidant, etc..)
10 Dr. Murat Mertoglu (BASF SE) 06/09/ 2012
+ +
+
+
+ -
- - - -
- - -
+ + + +
+
+ +
+
+
+ -
- - - -
- -
- +
+ + +
+
+
+ + +
+ +
+
- -
-
- - -
- +
+ + +
+ +
+
-
- -
- - -
-
a) steric b) electrostatic c) electrostatic + steric
stabilization
Confidential 11
12x weeks
at 40°C
12x weeks
at 40°C
Particle size
distribution d90 (µm)
without
d90 (µm)
with 2%
initial 3.4 3.3
after 12 weeks 10.3 5.0
CH2
O
OH
*
CH3
CH2
CH2
CH
*
RO
O
CH3
CH3
n
n
n
boscalid 250 g/l
antifreeze 70 g/l
dispersing agent a 20 g/l
dispersing agent b 30 g/l
antifoam 5 g/l
thickener 2 g/l
bactericide 2 g/l
inhibitor 2 g/l
water add 1 lt
no crystal growth with polymer, and so no nozzle blockage
Typical additives for continuous phase water
Inhibitor polymer
Typical additives for continuous phase solvent
EC, DC, OD,
─ solvent
─ emulsifier
─ dispersing agent,
─ thickener
─ adjuvants (to improve spreading, uptake, retention),
12 Dr. Murat Mertoglu (BASF SE) 06/09/ 2012
+ +
+
+
+ -
- - - -
- - -
+ + + +
+
+ +
+
+
+ -
- - - -
- -
- +
+ + +
+
+
+ + +
+ +
+
- -
-
- - -
- +
+ + +
+ +
+
-
- -
- - -
-
a) steric b) electrostatic c) electrostatic + steric
stabilization
Requirements for Liquid Formulations
Active loading 100g- 500 g /lt (in general)
Viscosity < 200 mPa/s
Chemical stability:
– maximum 5 % a.i. Decomposition allowed
– For 2 years and 8 weeks at 40°C
Physical stability
– at ambient temperature for 2- 3 years
– at 0°C to 40 °C for several day
30 µm 30 µm
Crystal
growth
30 µm
Flocculation Concentate
30 µm
Coalescence Phase
separation
X
13 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Dry (solid) Formulations
spontaneous
dispersibility
is requested!
Limited number additives technology intensive
Low cost of goods Relatively higher production cost !
14 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Delivery Properties
Structure of particles Absorption
Penetration
Retention or Anti-bouncing Spraying
Uptake
Fixation
Static surface tension
Evaporation / Adhesion
Wetting
Dynamic surface tension
Distribution
Contact angle
Spreading
An effective active and a stable formulation are not alone enough!
15 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
the smaller are the size of droplets, the larger is the drift problem!
Drift Reduction
Spraying (Atomization)
16 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Retention (Deposition)
R Rioboo et al. (2001). Outcomes from a drop impact on solid surfaces. At. Sprays 11:155–65
Retention
sprayed pesticide droplets must remain on the plant!
17 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Retention Improvement via Formulation
Epoxiconazole (SC) Epox.(SC) + Metco (EC) Epox. + Metco. (EC)
Source de
lumière
Générateur de
gouttelettes
Support
d’échantillon
Caméra: 250.000
prises/seconde
0
100
200
300
400
500
WaterSC (1) EC(1+2)
Sp
ray R
ete
nti
on
%
18 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
1s 10s 60s
Contact Angle
19 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Spreading
spreading is particularly important for contact fungicides
Water SC
Sp
read
ing
SE
20 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
2000 : 1 5000 : 1
better contact with leave surface: good for uptake & rain fastness
Adhesion REM Pictures Structure of particles
21 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
waxy layer and the cuticle barrier for active ingredient uptake
Cuticle Epicuticular wax
Barriers for Uptake of A.I.
Transverse section of a wheat leaf
Epicuticular waxes
Cuticle with
embedded waxes
Epidermal cells
“on leaf”
“in waxy layer”
“in leaf” (uptake)
Epidermal cell
Absorption
22 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Through the Barrier
after M. Riederer, Würzburg
a.i. diffusion path without adjuvant a.i. diffusion path with adjuvant
Special adjuvants and/or solvents opens channels in crystalline wax layer
Uptake depends:
on plant type
intrinsic mobility of active
used solvents and/or adjuvants (non ionic surfactants: fatty
alcohol alkoxylated)
Absorption
23 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
0 2 4 6 10 12 14 18 20 days 16 8
septoria tritici
No efficacy with fungicides Curative action Preventative action
spore-germination infection mycelial growth sporulation pycnidia
green leaf tissue chlorosis dry lesion + pycnidia
conazole
carboxamide
Superficial
hyphal
growth
Penetration
Sub-
epidermal
runner
hyphae
Latent
myce-
lium
Necro-
trophic
myce-
lium
Spore
germination
Pycnidium
formation
Cirrhus
production &
spore extrusino
It could be used effectively within 12 days after an infection to save the plants!
Formulation Development Exercise!
24 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Actives: boscalid + epoxiconazole + pyraclostrobin
Chose formulation type, but consider requirements & intrinsic
properties!
– uptake of epoxiconazole & pyraclostrobin: apply molecularly
dissolved form + adjuvant
– spreading of boscalid on the surface
– boscalid is not soluble in registered solvents
– pyraclostrobin has low melting point
– pyraclostrobin & boscalid: not compatible with adjuvants;
crystallization
– rain fastness
Formulation Development Exercise!
25 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
1stactive (a.i.)
solvent
2ndactive (a.i.)
water EC solution of
a.i in solvent
EW emulsion of
dissolved a.i in water
ME micro -
emulsion
SC dispersed a.i.
(crystalline in water
SE combination
of SC + EW
OD dispersion of
crystalline a.i in solvent
SL solution of
active in water
Formulation Development Exercise!
26 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Formulation Development Exercise
Pseudo= OD+ EC
Pseudo OD fulfills all requirements for maximum biological efficacy!
EC solution of
a.i in solvent
+
OD dispersion of
crystalline a.i in solvent
=
water
OD
dilution
OD dispersion of
crystalline a.i in solvent
1stactive (a.i.)
solvent
2nd (a.i.)+Solvent
Boscalid
conazole
+ strobin.
OD
27 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Formulation Development Ex.
OD vs. Tank Mix (SC + SE)
Uptake
OD provided improved uptake of epoxiconazole and pyraclostrobin
28 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
91
9
63
37
66
34
0
20
40
60
80
100
wash uptake
%
Boscalid (SC) + Pyrac.&Epoxi. (SE)
boscalid epoxiconazole pyraclostrobin
90
10 21
79
52 48
0
20
40
60
80
100
wash uptake
%
OD
boscalid epoxiconazole pyraclostrobin
Improved spreading for boscalid : better spreader in formulation
OD vs. Tank Mix (SC + SE)
Spreading
Spreading ~ 120 % Spreading > 1000%
29 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Rain Fastness
Via quantitative Determination of A.I. Uptake
new methods: quantitative determination of un-labeled a.i.s.
Analysis with LC-MS-MS
Drying Time
typically 1h
Application
Irrigation
Drying over night
Collection of leaves
not irrigated
irrigated
Drying over night
Collection of leaves
Active in&on leaf
Active in&on leaf
30 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
90
0
0
0 50 100
Untreated
OD
Tank Mix
85
7
7
0 50 100
80
0
6
0 50 100
without irrigation 15 min after application (20mm)
60 min after application (20mm)
• Glasshouse test brown rust
3 days curative: Application 3 days after inoculation
OD vs. Tank Mix (SC + SE)
Rain Fastness
Improved as rain fastness with = right formulation type for this mixture!
% brown rust attack
31 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Future: more sustainable pesticides formulations
More convenient for farmer
No compromise on performance
Less chemical /ha
Chemicals with better profile
More profitable
32 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Description of Technical Target
Perf
orm
ance
Sustainability
Typically EC
Typically SC
Free from critical
solvents & inerts
High performance Target
33 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
More Sustainable Formulation Example
Epox. Metc. Mixture with Tailored Polymer
Polymer CP 633, custom made for conazoles, partially replace solvents
30% more azole loading: 2 lt/ha instead of 3 lt/ha
– co-solvent, dispersing agent, adjuvant, retention improver,
beter rain fastness
with
CP633 without
CP633
Pe
rfo
rman
ce
Sustainability
Target
Enhanced bio-availability Performance
Less solvents Sustainability
Boost formul. properties Efficiency
Reduced volume Convenience
34 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
35
A.I. element
Hydrophilic element
Lipophilic element
Active ingredients
A.I. element
Hydrophilic element
Lipophilic element
Active ingredients
Diluted in water
How does polymer CP 633 works!
Polymer at least with three different functional groups 35 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Conazole Mixture in Polymer EC
Quick uptake allows strong curative action and excellent rain fastness
36 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Authorities:
tox & ecotox
profile
Customer:
Effective Product
Marketing:
Profitable product
Formulation
•Stability,
•Drift,
•Retention,
•Spreading,
•Uptake,
•Rain Fastness
•Tox & Ecology
•Efficacy
•Cost
• Manufacturing
•IP
•Stability,
•Drift,
•Retention,
•Spreading,
•Uptake,
•Rain Fastness
Different properties are improvable, but no perfect
formulation superior in all properties exists!
Good formulations are the ones that finds the best compromise among needs of customers, authorities, environment, and producers!
37 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Backup Slides!
38 Dr. Murat Mertoglu (BASF SE) 06/09/ 2012
Bead milling: basis for SC, SE, OD, etc…
Active ingredients
Formulants
Water
Bead mill
1. Rotor 2. Inlet 3. Grinding beads 4. Cooling jacket 5. Separation system
~ 200 µ ~ 80 % <2 µ
bead mill
SC
EC
SE
Beads
39 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)
Active ingredient
+ formulants
+ water
Wet milling
Drying air Exhaust air
Suspension
Dry (solid) Formulations
Wetable Granulate (WG) Fluidized bed granulation
40 06/09/ 2012 Dr. Murat Mertoglu (BASF SE)