Lab 03
Mixing & Filling Center
Industrial homogenization and filling technology for formulations that perform consistently
We run industrial mixing vessels from 500 L to 5,000 L with high-shear homogenizers that achieve particle size D90 below 5 μm for SC formulations, then validate every batch: active ingredient content analysis per CIPAC methods, stability testing at 54 °C / 14 days, with batch records documented and traceable per lot.
Specifications verified: 2026-08An agrochemical formulation is only as reliable as its homogenization. A single unmixed pocket or an uneven fill can compromise an entire batch — and in the field, inconsistent active ingredient content is not an inconvenience; it is a regulatory violation and a crop safety hazard. At {SITE.name}, we have invested in a dedicated Mixing & Filling Center that combines industrial-grade homogenization and filling equipment with rigorous process control and post-fill testing. Every batch we produce is documented, traceable, and certified to meet or exceed the requirements of FAO/WHO specifications and ICAMA registration standards.
The science behind the mix
Agrochemical mixing uses high-shear mechanical energy to reduce active ingredient particles to a controlled size distribution and distribute them uniformly throughout the carrier liquid. Unlike simple stirring, high-shear homogenization creates a true suspension or emulsion where every milliliter of product contains the same concentration of active ingredient — producing a batch that is homogeneous from first fill to last.
Mixing equipment and process control
Our mixing and filling centre is equipped with:
| Equipment | Capacity / Specification | Application |
|---|---|---|
| High-shear homogenizer 1 | 5,000 L, D90 < 5 μm | SC main batch mixing, active ingredient wet milling |
| High-shear homogenizer 2 | 2,000 L, D90 < 3 μm | ME and micro-emulsion preparation, adjuvant blending |
| CNC-controlled filling line | 100–1,000 mL/min, ±0.5% accuracy | Liquid filling into drums, bottles and jugs; weight verification per unit |
| WDG granulation line | Batch size 500–2,000 kg, fluid-bed dryer | Wet granulation, drying, sizing for water-dispersible granules |
Every mixing vessel is equipped with closed-loop temperature and viscosity monitoring. Process parameters — shear rate, mixing time, cooling temperature, fill volume — are programmed per formulation type and recorded in our Manufacturing Execution System (MES) for full traceability.
Batch quality tests — every batch, every lot
Batch integrity is verified through a mandatory four-test protocol:
- Visual inspection — 100 % of filled units are visually inspected for contamination, phase separation, incorrect fill level, or packaging defects. Reject rate threshold: 0.3 % of units.
- Active ingredient content analysis — A sample from each batch is analyzed per CIPAC methods. Acceptable range: ±5% of declared content for most formulation types.
- Stability testing — Every batch undergoes accelerated storage at 54 °C for 14 days per CIPAC MT 46. Active content must remain within specification after thermal stress.
- Physical properties verification — Suspension rate (SC), emulsion stability (EC), wettability and dispersibility (WDG/WP), and pourability are tested per CIPAC methods and compared against the approved reference sample.
Particle Size Distribution — High-Shear vs Conventional Mixing (SC 250 g/L)
High-shear homogenization consistently achieves 90-95 % of target particle size, well within FAO/WHO specifications for suspension concentrates.
Professional expertise
Our mixing team is led by a senior process engineer with 11 years of experience in agrochemical formulation and homogenization. Each operator completes a 6-month in-house certification programme before being allowed to manage production batches. Recertification is required annually, including a practical mixing and fill test evaluated against our internal Grade-A standard (active content within ±2% of target).
Custom mixing solutions for unique requirements
We understand that one mixing specification does not fit every formulation. Our Mixing & Filling Center routinely develops custom processing parameters for clients with special requirements:
- High-loading SC formulations — for formulations above 500 g/L active content, we validate homogenization parameters at elevated viscosity and document the process limits in the batch record.
- Temperature-sensitive actives — for actives that degrade above 40 °C, we implement closed-loop cooling and reduced-shear protocols that maintain particle size without thermal exposure.
- Multi-component tank mixes — formulations requiring in-line blending of two or more active ingredients are homogenized with sequential addition protocols to prevent precipitation or incompatibility.
Our commitment to you
Every batch we deliver carries our quality guarantee: if any lot fails content analysis or stability testing in normal storage within the shelf life, we replace the affected lot at no cost, and a root-cause investigation is performed to prevent recurrence. This is not simply a warranty — it is a commitment to continuous improvement driven by real-world batch data.
When you choose {SITE.name}, you are choosing formulations that are engineered, tested, and documented — not just mixed. That is the difference between a product that sprays and a product that performs.
Discuss your mixing & filling requirements
Custom batch specifications, formulation compatibility, or process validation.