Lab 04
Formulation Pilot Plant
Validating performance before the first production batch
We pilot-batch agrochemical formulations at 5–50 L scale — active content, co-formulant package, particle size distribution, and rheology — measuring suspensibility, emulsion stability, and shelf stability before committing to full-scale production. A week in the pilot plant returns the performance data that would take months of full-scale trial and error.
Specifications verified: 2026-08It is a common misconception that pilot-scale testing is reserved for pharmaceutical products. In reality, the performance of a crop protection formulation — a suspension concentrate or emulsifiable concentrate — is just as dependent on its physical-chemical properties as any regulated product. Active content uniformity, particle size distribution, suspensibility, and emulsion stability all have a dramatic effect on field efficacy and shelf life. At {SITE.name}, we operate a dedicated formulation pilot plant that allows us to quantify these effects at small scale — before committing raw materials and production line time to a full-scale batch.
Why pilot-test a formulation?
Testing at pilot scale (typically 5–50 L) gives us the ability to iterate formulation recipes rapidly and cost-effectively. A week in the pilot plant can generate the same stability and performance data that would require months of full-scale trial-and-error — and at a fraction of the cost.
Facility specifications
| Parameter | Specification |
|---|---|
| Pilot batch range | 5 L to 50 L, stainless steel and glass-lined vessels |
| High-shear mixer | Variable speed, max 6,000 RPM, temperature-controlled jacket |
| Sand mill | Basket-type, zirconia media, target D50 < 3 µm for SC formulations |
| Spray dryer | Lab-scale, inlet 180–220 °C, for WP and WDG prototype production |
| Stability chambers | 54 °C (accelerated), 40 °C (intermediate), 25 °C/60 % RH (long-term), ± 0.5 °C control |
| Instrumentation | HPLC, GC, laser particle size analyser, Brookfield viscometer, pH meter, emulsion stability apparatus |
Our test programme
A standard formulation development programme in our pilot plant follows this sequence:
- Pre-formulation screening — Active ingredient solubility, compatibility with co-formulant candidates, and initial pH adjustment are assessed in benchtop beaker trials.
- Pilot batch production — A 5–10 L batch is prepared using the high-shear mixer and sand mill. Process parameters (shear time, milling passes, addition order) are documented.
- Physical-chemical testing — Active content by HPLC/GC, particle size distribution by laser diffraction, suspensibility (CIPAC MT 161), emulsion stability (CIPAC MT 36), pH, and viscosity are measured at time zero.
- Accelerated stability — Samples are placed at 54 °C for 14 days and 40 °C/75 % RH for 28 days. Active content, suspensibility, sedimentation, and pH are re-measured at each interval.
- Spray performance (optional) — Diluted formulation is tested in a spray tower for droplet size distribution, drift potential, and coverage uniformity on leaf surfaces.
- Data analysis & recommendations — A full report is delivered with comparative charts, stability curves, and specific formulation adjustments recommended for full-scale production.
Typical Pilot Plant Results — Suspensibility Over Time (25% SC, 54 °C)
Suspensibility measured per CIPAC MT 161. Agrospear formulations maintain ≥ 90 % suspensibility after 14 days at 54 °C, compared to typical industry products that drop below 80 %.
Expert team
Our pilot plant is operated by a senior formulation chemist with a PhD in agrochemical chemistry and 8 years of formulation development experience at a major international crop protection company. He is supported by a technician who prepares all batches and performs routine testing. The team follows CIPAC (Collaborative International Pesticides Analytical Council) methods to ensure that every test is repeatable, traceable, and internationally defensible.
Pilot testing for custom formulation development
Our pilot plant is not only used for house-developed formulations — we regularly run test programmes for clients who want to validate a custom formulation or investigate a stability issue:
- Formulation comparison — Two or more candidate co-formulant packages tested under identical conditions, providing an objective suspensibility/stability comparison to inform your recipe choice.
- Particle size optimisation — Milling parameters and media combinations are tested in various configurations to quantify their contribution to particle size reduction and suspensibility improvement.
- Stability study — Active content and physical properties are mapped across temperature and humidity conditions, allowing you to specify the right shelf life and storage requirements for your target market.
Why test with us?
We do not just give you a set of raw numbers. Our reports translate pilot data into actionable formulation recommendations: "Increase dispersant from 3 % to 5 % to improve suspensibility above 95 %", "Reduce milling passes from 6 to 4 to lower viscosity without compromising D90", or "Add a pH buffer at 0.2 % to prevent hydrolysis at elevated temperatures". You leave with a clear understanding of what to change and why.
Our pilot plant is also available for independent third-party testing on a fee-for-service basis. If you are developing a formulation and want an unbiased, professionally executed stability assessment, we welcome your enquiry.
Book a pilot plant test session
Whether you need a full development programme or a single comparative test, we can accommodate your schedule.