Process
Manufacturing Process
From raw material to market-ready formulation —every step under our control
Unlike brands that outsource production to third-party factories, Agrospear owns and operates its entire manufacturing chain. This vertical integration allows us to maintain strict quality control at every stage, respond quickly to custom requirements, and deliver consistent product quality batch after batch. Here is how a crop protection product is built in our facility.
Material Receipt & Inspection
Every incoming batch of technical-grade active ingredient, solvent, adjuvant, and packaging material is inspected against specification. Raw material samples are tested for active content by HPLC/GC, purity, moisture content, and physical properties before release to production. Non-conforming materials are quarantined and returned.
Automatic Weighing & Dosing
<p>Approved materials are weighed and dosed by the automatic PLC-controlled system with ±0.1% accuracy. Computer-optimised batching calculates precise quantities for each formulation to minimise waste —typically below 3%. Weighed components are labelled by formulation and batch, then transferred to the compounding workshop.</p>
Compounding & High-Shear Mixing
Active ingredients, dispersants, emulsifiers, and carriers are compounded in high-shear mixers at controlled speeds of 3,000–10,000 rpm. SC formulations are pre-mixed before sand milling. EC and SL formulations are blended in jacketed temperature-controlled tanks. Particle size is monitored throughout the process.
Sand Milling & Formulation Processing
SC and WDG formulations are processed through sand mills to achieve target particle size distributions (D50 1–5 μm for SC, D50 20–40 μm for WDG). WDG and WP products are produced by spray drying or fluid bed granulation. Each batch is checked for particle size, viscosity, pH, and suspensibility before proceeding.
Labeling & Decoration
Product containers are labeled using automatic labeling machines for multi-language GHS-compliant labels and inkjet coders for batch and date coding. Labels are verified against approved artwork and regulatory requirements.
Filling & Sealing
Drums, jerry cans, and bottles are filled, sealed, and checked on automatic filling machines. Each batch follows a 100-point filling and packaging checklist with mandatory sign-off at each stage.
Quality Testing & Inspection
Every completed batch undergoes mandatory quality gate: active content verification by HPLC/GC, specification check (suspensibility, pH, viscosity, particle size), and 14-day stability test at 54°C per CIPAC MT 46. Custom and prototype formulations also receive field efficacy verification where required.
Packing & Shipping
Finished products are palletized per procedure, packed in export-grade packaging, and loaded for shipment. Each package is labelled with product name, batch number, and destination. We coordinate with freight forwarders for FCL and LCL container shipments worldwide.
Inspection Evidence
Every Stage Leaves a Record — Photos & Reports
Below are the actual inspection photos and test-report dossiers from our seven controlled quality gates. Each PDF is a real bilingual record you can download and audit — the same records that back every batch in the 5-year ERP traceability archive. See the full 7-stage flow on /manufacturing/quality-control.
PPM — Project Quality Planning
The pre-production meeting locks scope, the golden sample and the Quality Inspection Plan before the line starts. Unresolved items block production release.
Download QIP (PDF)
IQC — Incoming Material Inspection
Every incoming batch of active ingredients, solvents and packaging is checked against the approved spec. Non-conforming lots are quarantined and rejected before release to the line.
Download IQC reports (PDF)
IPQC / FAI — In-Process Control
The first article is verified against the locked baselines and every shift keeps patrol checks on the line. FAI approval version-locks formulation, specifications and BOM.
Download IPQC reports (PDF)
Stability & Specification Verification
100% of completed batches — not a sample — get a 14-day stability test at 54°C with automatic reject for active content deviation above ±2%. One record per batch.
View QC/QA document library
FQC — Final Product Inspection
Finished batches are measured against specification limits and visually inspected under standard lighting against the approved golden sample.
Download FQC reports (PDF)
PSI — Packaging & Pre-Shipment Inspection
The packed shipment is checked 100% against the customer-approved BOM — barcode scan (Grade ≥ B), container markings and packaging integrity before loading.
Download PSI reports (PDF)
Shipment Release & Traceability
Quality signs off the batch only when all six previous gates are closed. Batch numbers are mapped to the shipment and the dossier is handed over with the delivery.
Download release reports (PDF)See our equipment and machinery
Explore the industrial-grade equipment behind every Agrospear formulation.
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