Lab 02
Formulation Engineering Studio
Active ingredient integration, co-formulant optimization, custom formulation design
Custom crop protection formulations are designed in-house with systematic active ingredient selection, co-formulant screening, and particle size optimization — every formulation is tested for suspensibility, emulsion stability, and pH compliance with a mandatory specification window before pilot batching. A custom formulation takes 7–14 days to prototype; full production validation adds 15–20 days to the 25–35 day production lead time, with MOQ confirmed by project configuration (see our MOQ guide).
Specifications verified: 2026-08The formulation of a crop protection product — its active ingredient ratio, co-formulant package, particle size distribution, and rheology profile — determines how it performs, disperses, and delivers efficacy in the field. At {SITE.name}, our Formulation Engineering Studio combines active ingredient screening, co-formulant optimization, particle size engineering, and production experience to deliver formulations optimised for their intended use: foliar spray, seed treatment, or soil application. Every custom formulation starts from your specification, not a generic recipe from a catalogue.
Where efficacy meets physical stability
An agrochemical formulation is a dispersion system: active ingredient particles are suspended or dissolved within a carefully balanced matrix of co-formulants, holding the product stable at specification concentration while the rheology and particle size distribution control how the product disperses and performs in the spray tank. We design the formulation, simulate the stability profile, and validate the result in-house before a single pilot batch is produced.
Design tools and standards
Our formulation engineering environment includes:
| Capability | Instrument / Method | Application |
|---|---|---|
| Active content analysis | HPLC / GC (CIPAC methods) | Active ingredient quantification, impurity profiling, batch consistency |
| Particle size engineering | Laser particle size analyser (Malvern) | D50/D90 control, suspensibility prediction, milled particle distribution |
| Rheology profiling | Rotational viscometer (Brookfield) | Viscosity at shear rates, thixotropy, pourability, sprayability |
| Co-formulant screening | Design of Experiments (DoE) | Surfactant selection, dispersant optimization, stabiliser package |
| Stability simulation | 54 °C accelerated stability chambers | Shelf life prediction, sedimentation rate, phase separation |
Our engineering workflow
Every formulation design, whether a standard model or a fully custom project, follows a rigorous five-stage process:
- Concept & requirements gathering — We define target crop and pest spectrum, application method (foliar, seed treatment, soil), target active ingredient content, formulation type (SC, EC, WP, WDG, SL, ME, CS, FS), and any special requirements (rainfastness, drift control, tank-mix compatibility).
- Co-formulant screening & DoE — The surfactant, dispersant, wetting agent, and stabiliser candidates are screened in a fractional-factorial design. suspensibility, emulsion stability, and viscosity are measured for each combination.
- Particle size optimisation — The milled suspension is analysed by laser diffraction. D50 and D90 targets are set per formulation type (e.g., SC: D50 < 3 µm, D90 < 8 µm). Milling parameters are iteratively adjusted.
- Rheology & stability validation — Viscosity is measured at multiple shear rates. Accelerated stability at 54 °C for 14 days is performed; suspensibility ≥ 90 % and no sedimentation are mandatory.
- Design review & release — The complete formulation package (active content certificate, particle size report, stability data, rheology profile, co-formulant bill of materials) is reviewed by our senior formulation chemist before release to the pilot plant.
Stability Results — 25% SC A.I. Formulation (14 Days at 54 °C)
Customisation: your formulation, your rules
No two brands have identical requirements. A broad-acre herbicide needs a stable SC with low viscosity for aerial spraying; a vegetable fungicide needs a WDG with excellent wetting for backpack application; a seed treatment line needs an FS with film-forming and colourant compatibility. We do not force your range into pre-existing recipes — we design from your specification upward.
Examples of recent custom formulation engineering projects:
- A 240 g/L SC herbicide for a broad-acre brand, with a custom dispersant package achieving 96 % suspensibility and 18-month shelf stability.
- A 80 % WP fungicide for a vegetable crop portfolio, with optimised wetting agents for backpack spray application at 200 L/ha.
- A 350 g/L FS seed treatment for a cereal programme, with film-forming polymers and red colourant for planting visibility.
Our engineers
The studio is led by a senior formulation chemist with 14 years of experience in agrochemical formulation development, supported by two chemists specialised in particle size engineering and rheology. All three hold advanced degrees in chemistry or chemical engineering from internationally recognised universities, and the team works directly with our production floor to ensure every formulation is manufacturable at container scale.
Partner with us on your next formulation
From the first active ingredient selection to the final stability report, our Formulation Engineering Studio is your partner in creating a crop protection product that is not just mixed — but engineered. We invest the optimisation hours upfront so that every co-formulant, every milling pass, and every viscosity measurement is there for a reason.
Whether you need a minor modification to an existing formulation or a completely clean-sheet design, we are ready to discuss your requirements.
Start your formulation design consultation
Tell us about your target crops and pest spectrum and we will propose an engineering path.