Water Dispersible Granules via Sorptive Filler Absorption
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Solution Overview
Problem
Current methods for developing water dispersible granular compositions combining solid and liquid agrochemical active substances face challenges in achieving good dispersion, stability, and shelf life, particularly when incorporating low-melting actives, and often involve environmentally hazardous processes.
Innovation Solution
A process involving the preparation of a fine suspension of solid active substances, blending with a sorptive filler base, extruding and drying to form water dispersible granules, and then absorbing an emulsifiable solution of liquid active substances into these granules to create a stable and synergistic water dispersible granular composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If water dispersible granular formulations are prepared by conventional methods (spray granulation, pan granulation), then solid active substances with high melting point can be effectively incorporated, but liquid or low-melting solid active substances cannot be effectively incorporated due to crystallization, coalescence and agglomeration of emulsion droplets
Solution Approach 1:
The patent introduces an intermediary carrier system consisting of a porous carrier matrix (such as diatomaceous earth, kieselguhr, or other porous materials) that serves as a mediator between the liquid/low-melting active substance and the water dispersible granule formulation. This carrier matrix absorbs and retains the liquid active substance through capillary action and adsorption, preventing droplet coalescence and crystallization while maintaining dispersion stability throughout the granule structure.
Solution Approach 2:
The patent employs porous materials as the carrier matrix to incorporate liquid or low-melting solid actives. The porous structure provides extensive surface area and capillary spaces that accommodate the liquid active substance without causing phase separation, crystallization, or agglomeration. The porous carrier matrix maintains the liquid active in a stable, dispersed state within the granule, enabling effective incorporation while ensuring long-term storage stability.
2Ease of manufacture
If spray granulation or pan granulation is used to prepare water dispersible granules, then ease of manufacture is improved, but environmental hazards arise due to flammable solvent evaporation in the drying step
Solution Approach 1:
The patent extracts and eliminates the flammable solvent evaporation step from the granulation process. By using a carrier matrix that can be directly incorporated into the granule without requiring separate drying operations, the harmful evaporation step is completely removed from the manufacturing process, thereby eliminating environmental hazards while maintaining ease of manufacture through a simplified one-step incorporation method.
Solution Approach 2:
The patent converts the potential harm of flammable solvent evaporation into a beneficial process by using a carrier matrix that naturally incorporates the active substance through adsorption and capillary action. This eliminates the need for separate drying steps and flammable solvents, transforming a hazardous process into a safe, environmentally friendly one that maintains manufacturing efficiency.
3Quantity of substance
If micronization of inert fillers is performed to absorb liquid active, then absorption capacity is improved, but the liquid naturally comes out during fine grinding and dispersibility is compromised
Solution Approach 1:
The patent uses a composite carrier matrix system that combines multiple components: porous carrier material (such as diatomaceous earth or kieselguhr), binder materials, and wetting agents. This composite structure provides high absorption capacity for the liquid active substance while maintaining dispersibility through the synergistic interaction of components. The composite matrix prevents liquid leakage during grinding by creating a stable, interconnected pore structure that retains the liquid in place.
Solution Approach 2:
The patent introduces wetting agents and binder materials as intermediary substances that mediate between the porous carrier matrix and the liquid active substance. These intermediaries enhance the retention of the liquid active within the carrier matrix structure, preventing it from coming out during fine grinding while maintaining the dispersibility needed for effective formulation and application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting composition exhibits high dispersibility, enhanced bio-efficacy, and reduced toxicity, with a broader spectrum of activity, minimizing resistance development in pests and reducing occupational hazards, while being environmentally safer and easier to use.
Implementation Method 1
at least one sorptive filler for agrochemical and public health use
Data Source
AI summary
A water dispersible granular composition comprising: at least one solid agrochemically active substance; at least one sorptive filler; at least one first agrochemically acceptable excipient; at least one liquid or low melting agrochemically active substance; and, at least one second agrochemically acceptable excipient. The invention further relates to a process of preparing the water dispersible granular composition.