A system for producing saponin-based pesticide formulations from plant extracts

Abstract

A system for producing saponin-based pesticide formulations from plant extracts, comprising: (a) an extraction unit configured to extract saponins from plant materials selected from the group consisting of Yucca aloifolia L., Glycine max (L.) Merr., Sapindus mukorossi Gaertn., Trigonella foenumgraecum L., Linum usitatissimum L. and Acacia concinna (Willd.) DC; b) a microemulsion formulation unit configured to produce microemulsion formulations containing methyl soyate as the oil phase, Galaxy ® MW 257 as emulsifier and surfactant, water as continuous phase and plant extract at a concentration of 10% (w / w); c) an emulsifiable concentration formulation manufacturing unit configured to produce emulsifiable concentration formulations containing methyl soyate as primary solvent, polyoxyethylene sorbitol hexaoleate and Tween® 20 as emulsifiers, butanol and polyvinyl alcohol as co-solvents and adhesives, respectively, and plant extract in a concentration of 10% (w / w) as active ingredient; and d) a quality control unit configured to carry out quality tests.

Description

FIELD OF THE INVENTION

[0001] The present disclosure relates to a system for producing saponin-based pesticide formulations from plant extracts. BACKGROUND OF THE INVENTION

[0002] Due to the increasing demand for environmentally friendly and sustainable solutions, there is growing interest in the use of natural emulsifiers for the production of microemulsions and emulsifiable concentrates, particularly in agriculture. Microemulsions are thermodynamically stable nanoscale dispersions and enable the efficient delivery of bioactive compounds. However, they are traditionally based on synthetic surfactants, which may not be compatible with environmental or safety objectives.

[0003] Saponins, a common class of plant surfactants, offer promising emulsifying properties thanks to their amphiphilic molecular structure and high surface activity. They are widely distributed across various plant families, generally considered safe, and already used in many industries due to their ability to form and stabilize emulsions. Their natural origin, coupled with additional biological benefits such as antimicrobial and antioxidant activity, makes them attractive for agricultural applications.

[0004] Despite their advantages, the reliable and scalable synthesis of saponin-based microemulsions and emulsifiable concentrates remains a challenge. Variability in plant sources, extraction, and formulation techniques can impact performance and commercial viability. Therefore, there is a clear need for a system specifically designed for the synthesis of saponin-based microemulsions and emulsifiable concentrate formulations using plant extracts for agricultural applications. Summary of the invention

[0005] The present disclosure relates to a system for producing saponin-based pesticide formulations from plant extracts. The system integrates extraction, formulation preparation, quality control, and storage functions to produce both microemulsions and emulsifiable concentration formulations for agricultural applications.

[0006] The present disclosure aims to provide a system for producing saponin-based pesticide formulations from plant extracts. The system comprises: an extraction unit configured to extract saponins from plant materials selected from the group consisting of Yucca aloifolia L., Glycine max (L.) Merr., Sapindus mukorossi Gaertn., Trigonella foenumgraecum L., Linum usitatissimum L., and Acacia concinna (Willd.) DC; a microemulsion formulation unit for producing microemulsion formulations containing methyl soyate as the oil phase, Galaxy ® MW 257 as emulsifier and surfactant, water as the continuous phase and plant extract at a concentration of 10% (w / w); an emulsifiable concentration formulation unit for the preparation of emulsifiable concentration formulations containing methyl soyate as the primary solvent, polyoxyethylene sorbitol hexaoleate and Tween ®20 as emulsifiers, butanol and polyvinyl alcohol as co-solvents and adhesives, respectively, and plant extract at a concentration of 10% (w / w) as the active ingredient; and a quality control unit to conduct quality tests.

[0007] An object of the present disclosure is to provide a system for producing saponin-based agricultural formulations from plant extracts.

[0008] Another object of the present disclosure is a system capable of extracting saponins from several plant species, including Yucca aloifolia L., Glycine max (L.) Merr., Sapindus mukorossi Gaertn., Trigonella foenumgraecum L., Linum usitatissimum L. and Acacia concinna (Willd.) DC and converting them into stable agricultural formulations.

[0009] Another object of the present disclosure is to provide a system for producing a microemulsion formation using the plant extract.

[0010] To provide formulation with emulsifiable concentration (EC) using the plant extract.

[0011] Another object of the present disclosure is to conduct quality control tests on the prepared formulations.

[0012] To further clarify the advantages and features of the present disclosure, the invention will be explained in more detail with reference to specific embodiments illustrated in the accompanying drawings. These drawings illustrate only typical embodiments of the invention and are therefore not to be construed as limiting its scope. The invention will be described and explained in more detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE CHARACTERS

[0013] These and other features, aspects, and advantages of the present disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like characters represent like parts throughout. Fig. 1 shows a block diagram of a system for producing saponin-based agricultural formulations from plant extracts according to an embodiment of the present disclosure; Fig. Figure 2 shows a table with the composition of the saponin plant extract for the microemulsion (ME) formulation according to an embodiment of the present disclosure. Fig. 3 illustrates a table showing the composition of the saponin plant extract for an emulsifiable concentration formulation according to an embodiment of the present disclosure.

[0014] Those skilled in the art will also appreciate that the elements in the drawings are shown for convenience and are not necessarily to scale. For example, the flowcharts illustrate the method by key steps to enhance understanding of aspects of the present disclosure. Moreover, with respect to device construction, one or more components of the device may be represented in the drawings by conventional symbols, and the drawings may show only the specific details relevant to understanding embodiments of the present disclosure in order not to clutter the drawings with details that would be readily apparent to those skilled in the art after reading the present description. DETAILED DESCRIPTION:

[0015] For a better understanding of the principles of the invention, reference is made below to the embodiment illustrated in the drawings and described in specific language. However, the scope of the invention is not limited thereby. Changes and further modifications to the illustrated system, as well as further applications of the principles of the invention, are possible, as would normally occur to one skilled in the art to which the invention pertains.

[0016] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be limiting thereof.

[0017] References in this specification to "one aspect," "another aspect," or similar expressions mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, the occurrences of the terms "in one embodiment," "in another embodiment," and similar expressions throughout this specification may or may not all refer to the same embodiment.

[0018] The terms "comprises," "having," or other variations thereof are intended to cover non-exclusive inclusion, such that a process or method comprising a list of steps not only includes those steps, but may also include other steps not expressly listed or inherent in such process or method. Likewise, the statement "comprises" with respect to one or more devices, subsystems, elements, structures, or components does not exclude, without further limitation, the existence of other devices, other subsystems, elements, structures, or components, or additional devices, additional subsystems, additional elements, additional structures, or additional components.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. The system, methods, and examples provided herein are for illustrative purposes only and should not be considered limiting.

[0020] Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.

[0021] Fig. 1 shows a block diagram of a system (100) for producing saponin-based agricultural formulations from plant extracts according to an embodiment of the present disclosure.

[0022] Referring to Fig. 1, the system (100) comprises: an extraction unit (102) configured to extract saponins from plant materials selected from the group consisting of Yucca aloifolia L., Glycine max (L.) Merr., Sapindus mukorossi Gaertn., Trigonella foenumgraecum L., Linum usitatissimum L. and Acacia concinna (Willd.) DC; a microemulsion formulation unit (104) configured to produce microemulsion formulations comprising methyl soyate as the oil phase, Galaxy ® MW 257 as emulsifier and surfactant, water as the continuous phase and plant extract at a concentration of 10% (w / w); an emulsifiable concentration formulation unit (106) configured to produce emulsifiable concentration formulations comprising methyl soyate as the primary solvent, polyoxyethylene sorbitol hexaoleate and Tween ®20 as emulsifiers, butanol and polyvinyl alcohol as co-solvents or adhesives, and plant extract in a concentration of 10% (w / w) as active ingredient; and a quality control unit (108) configured to perform quality tests.

[0023] In one embodiment, the extraction unit (102) is configured to keep the plant material in powder form and use methanol for saponin extraction with magnetic stirring function.

[0024] In one embodiment, the microemulsion formulation unit (104) comprises a first phase preparation component configured to mix distilled water at a concentration of 60% (w / w) with the emulsifier Galaxy ®MW 257 at a concentration of 20% (w / w). To achieve a stable phase, several different concentrations of water and emulsifier were tested, including ratios of 50:10, 60:30, 40:80, 100:0, and 60:20.

[0025] In one embodiment, the microemulsion formulation unit (104) comprises a second phase preparation component configured to maintain the plant extract at 10% (w / w) with methyl soyate at 10% (w / w) as an oil carrier.

[0026] In one embodiment, the microemulsion formulation unit (104) further comprises a final phase preparation component configured to mix or add the plant extract and methyl soyate to the water and emulsifier phases using a magnetic stirrer to facilitate emulsification at room temperature.

[0027] In one embodiment, the emulsifiable concentration formulation unit (106) is configured to prepare a first phase wherein methyl soyate (78-79.8% w / w) is mixed as the primary solvent with the mulifier polyoxyethylene sorbitol hexaoleate (5-7% w / w) and Tween ® 20 (2-4% w / w), with the emulsifier components being added simultaneously while stirring with a magnetic stirrer.

[0028] In one embodiment, the emulsifiable concentration formulation unit (106) is further configured to prepare a second phase by mixing plant extracts of selected saponin-containing plants (10% w / w) with the co-solvent butanol (2% w / w), using an additional co-solvent (DMSO, 3% w / w) in the case of a formulation for saponin derived from Yucca aloifolia.

[0029] In one embodiment, the emulsifiable concentration formulation unit (106) is further configured to prepare a final phase by adding a plant extract and a co-solvent mixture to the methyl soyate and emulsifier phase using a magnetic stirrer to facilitate emulsification at room temperature.

[0030] In one embodiment, the system (100) further comprises a storage unit (110) configured to store prepared formulations in amber containers for preservation.

[0031] The present invention comprises a sophisticated system for the comprehensive production of saponin-based agricultural formulations from various plant sources. The system addresses the growing demand for environmentally friendly agricultural solutions by utilizing natural saponin compounds from selected plant materials. The invention integrates multiple processing units that work in a coordinated manner to deliver high-quality agricultural formulations for commercial applications.

[0032] The system's extraction unit is configured to process plant materials from six different species known for their saponin content. These include Yucca aloifolia L., Glycine max (L.) Merr., Sapindus mukorossi Gaertn., Trigonella foenumgraecum L., Linum usitatissimum L., and Acacia concinna (Willd.) DC. The unit maintains plant materials in powder form and uses a methanol-based extraction with magnetic stirring capabilities to ensure efficient saponin recovery from the plant matrices. The pods of the plant material are crushed to a fine powder using a mortar and pestle. An additional 10 g of powdered material is weighed using a balance and mixed with 100 ml of methanol. The extraction was carried out for 30 minutes using a magnetic stirrer. The resulting extracts were filtered using Whatman No. 41 filter paper.

[0033] Fig. Figure 2 shows a table with the composition of the saponin plant extract for the microemulsion (ME) formulation according to an embodiment of the present disclosure.

[0034] The microemulsion formulation unit is designed to produce stable microemulsion formulations using a carefully balanced three-phase system. The first phase ensures precise ratios of distilled water (60% w / w) and Galaxy ® MW 257 emulsifier (20% w / w). The system can test various concentration ratios to achieve optimal stability. The second phase integrates the plant extract (10% w / w) with methyl soyate (10% w / w) as an oil carrier, while the final phase enables controlled mixing of these phases by magnetic stirring at room temperature to achieve optimal emulsification.

[0035] In one implementation, a concentration of 10% (w / w) of each plant extract is selected to prepare a microemulsion formulation. Methyl soyate was selected as the oil phase, while Galaxy ® MW 257 served as both an emulsifier and a surfactant. Water was used as the continuous phase. The preparation of the first phase involves mixing distilled water (60% w / w) with the Galaxy emulsifier. ®MW 257 (20% w / w), where several different concentrations of water and emulsifier were tested, including ratios of 50:10, 60:30, 40:80, 100:0, and 60:20 to obtain a stable phase. In this phase, water served as the continuous phase and the emulsifier was added gradually with continuous stirring using a magnetic stirrer. Preparation of the second phase involves gradually mixing plant extract (10% w / w) with methyl soyate (10% w / w) as the oil carrier, with mixing using a magnetic stirrer. Preparation of the final phase involves slowly adding the plant extract and methyl soyate to the water and emulsifier phase with magnetic stirrer to facilitate emulsification at room temperature. The process occurs spontaneously, with stirring improving the homogenization rate.After production, the microemulsion formulation undergoes quality controls according to FAO and CIPAC quality control standards. The composition of the saponin plant extract for the microemulsion formulation (ME) is shown in the table below. Fig. 2 shown.

[0036] Fig. 3 illustrates a table showing the composition of the saponin plant extract for an emulsifiable concentration formulation according to an embodiment of the present disclosure.

[0037] The unit for formulating emulsifiable concentrations operates with a parallel three-phase system specifically designed for concentrated formulations. The first phase involves the preparation of methyl soyate (78-79.8% w / w) as the primary solvent in combination with polyoxyethylene sorbitol hexaoleate (5-7% w / w) and Tween. ®20 (2-4% w / w) as emulsifiers. The second phase preparation comprises plant extract (10% w / w) with butanol (2% w / w) as a co-solvent, with special precautions for Yucca aloifolia formulations requiring additional DMSO (3% w / w) as a co-solvent. The final phase preparation component ensures proper integration of the extract-co-solvent mixture with the solvent-emulsifier phase through controlled magnetic stirring.

[0038] In one implementation, the system prepares the formulation of the emulsifiable concentration (EC) in three different phases, using: 10% (w / w) concentration of each plant extract as active ingredient (AI); methyl soyate as the primary solvent for all formulations; polyoxyethylene sorbitol hexaoleate and Tween ®20 as emulsifiers and spreading agents; and butanol and polyvinyl alcohol as co-solvents and adhesives, respectively, to achieve formulation stability. The system prepares the first phase by mixing methyl soyate as the primary solvent (78-79.8% w / w) with the emulsifier polyoxyethylene sorbitol hexaoleate (5-7% w / w) and Tween ®20 (2-4% w / w), whereby various combinations of the emulsifiers were tested in different formulations to obtain a stable phase. The emulsifier component is added simultaneously with constant stirring using a magnetic stirrer to ensure uniform dispersion. For the preparation of the second phase, the system is configured such that the plant extract of selected saponin-containing plants (10% w / w) is mixed with the co-solvent butanol (2% w / w), whereby for certain formulations an additional co-solvent (DMSO, 3% w / w) was used for the Yucca aloifolia, whereby mixing was carried out slowly with constant stirring to improve the mixture and ensure stability.To prepare the final phase, the system is configured so that the plant extract and cosolvent mixture is slowly added to the methyl soyate and emulsifier phase while stirring with a magnetic stirrer to facilitate emulsification at room temperature. Stirring ensures homogeneity and a stable emulsifiable concentrate. The composition of the saponin plant extract for the emulsifiable concentration (EC) formulation is shown in the table in . Fig. 3 shown.

[0039] The system features a dedicated quality control unit that conducts comprehensive testing to ensure formulation consistency and efficacy. Additionally, the prepared formulations are stored in a storage unit in amber containers to protect them from light exposure and ensure long-term product stability. This integrated approach ensures that the system delivers consistent, high-quality saponin-based agricultural formulations that meet commercial standards and regulatory requirements.

[0040] The drawings and the foregoing description illustrate examples of embodiments. Those skilled in the art will recognize that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be separated into multiple functional elements. Elements of one embodiment may be added to another embodiment. For example, the order of the processes described herein may be changed and is not limited to the manner described herein. Furthermore, the actions of a flowchart need not be implemented in the order shown; nor do all actions need to be performed. Also, actions that are not dependent on other actions may be performed in parallel with the other actions. The scope of the embodiments is in no way limited by these specific examples.Numerous variations, whether explicitly stated in the specification or not, such as differences in structure, dimensions, and use of materials, are possible. The scope of the embodiments is at least as broad as indicated in the following claims.

[0041] Advantages, further benefits, and solutions to problems have been described above with reference to specific embodiments. However, the advantages, advantages, solutions to problems, and any components that may result in an advantage, advantage, or solution occurring or becoming more apparent are not to be construed as critical, required, or essential features or components of any or all of the claims. REFERENCES 100 A system for producing saponin-based agricultural formulations from plant extracts. 102 Extraction system 104 Microemulsion Formulation Unit 106 Emulsifiable Concentration Formulation Unit 108 Quality Control Unit 110 storage unit

Claims

[1] A system for the production of saponin-based pesticide formulations from plant extracts, comprising: a) an extraction unit configured to extract saponins from plant materials selected from the group consisting of Yucca aloifolia L., Glycine max (L.) Merr., Sapindus mukorossi Gaertn., Trigonella foenumgraecum L., Linum usitatissimum L. and Acacia concinna (Willd.) DC; b) a microemulsion formulation unit configured to produce microemulsion formulations using methyl soyat as the oil phase, Galaxy ® MW 257 as emulsifier and surfactant, water as continuous phase and plant extract at a concentration of 10% (w / w); c) a unit for the production of emulsifiable concentration formulations, configured to produce emulsifiable concentration formulations using methyl soyate as the primary solvent, polyoxyethylene sorbitol hexaoleate and tween® 20 as emulsifiers, butanol and polyvinyl alcohol as co-solvents or adhesives, and plant extract at a concentration of 10% (w / w) as the active ingredient; and d) a quality control unit configured to perform quality tests. [2] System according to claim 1, wherein the extraction unit is configured to hold the plant material in powder form and uses methanol for saponin extraction with magnetic stirring function. [3] System according to claim 1, wherein the microemulsion formulation unit comprises a component for producing the first phase, which is configured to combine distilled water at a concentration of 60% (w / w) with the emulsifier Galaxy ®MW 257 is maintained at a concentration of 20% (w / w), with several different concentrations of water and emulsifier being tested to achieve a stable phase, including ratios of 50:10, 60:30, 40:80, 100:0 and 60:

20. [4] System according to claim 1, wherein the microemulsion formulation unit comprises a preparation component for the second phase configured to maintain the plant extract at 10% (w / w) with methyl soyat at 10% (w / w) as the oil carrier. [5] System according to claim 1, wherein the microemulsion formulation unit further comprises a component for preparing the final phase, which is configured to mix or add the plant extract and the methyl soyate to the water and emulsifier phase, wherein a magnetic stirrer is used to facilitate emulsification at room temperature. [6] System according to claim 1, wherein the formulation unit for emulsifiable concentrations is configured to produce a first phase, wherein methyl soyalate (78-79.8% w / w) is used as the primary solvent with the emulsifier polyoxyethylene sorbitol hexaoleate (5-7% w / w) and Tween ® 20 (2-4 % w / w) is mixed and the emulsifier components are added simultaneously while stirring with a magnetic stirrer. [7] System according to claim 1, wherein the unit for formulating emulsifiable concentrations is further configured to prepare a second phase by mixing plant extracts of selected saponin-containing plants (10% w / w) with the co-solvent butanol (2% w / w), wherein in the case of a formulation for saponin obtained from Yucca aloifolia an additional co-solvent (DMSO, 3% w / w) is used. [8] System according to claim 1, wherein the formulation unit for emulsifiable concentrations is further configured to prepare a final phase by adding plant extract and a co-solvent mixture to the methyl soyate and emulsifier phase, using a magnetic stirrer to facilitate emulsification at room temperature. [9] System according to claim 1, further comprising a storage unit configured to store prepared formulations for preservation in amber-colored containers.

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