Manufacturing Suspension Concentrates Via Bead Milling

Suspension Concentrates

We have two segregated suspension concentrate (or ‘flowables’) facilities at Safapac where we are able to manufacture stable suspensions. These consist of an insoluble solid active ingredient dispersed at (conventionally) a high concentration in liquid.

The high density of some actives makes them unsuitable for formulation into stable suspensions; hence a particle size reduction procedure has to first take place for this to be possible. We achieve this through bead milling techniques.

Suspension concentrate plant capabilities

Our suspensions plant is capable of manufacturing both large and small-scale quantities of product and has the following features:

Multiple-active formulations
Continuous batch process plant design
Particle size reduction with Fryma colloid mills and wet bead milling using WAB KD280 Dyno Mills
Sub micron particle size reduction capabilities
Output of 24,000L/day achievable subject to analytical specification and formulation
24/7 shift operation
Bulk FIBC and case / sack powder handling capability
Stringent clean down process in the changeover between campaigns – verified by laboratory analysis to ensure this meets our strict criteria and ECPA guidelines

Segregated herbicide suspension concentrate plant

In 2015, we installed a brand new suspension plant – this has enabled us to increase the production of these suspension concentrate products.

One of the main factors to consider in a manufacturing plant such as this is the potential for cross contamination – the new plant is therefore segregated for the manufacture of herbicides (i.e. highly potent actives) only. This is inline with the CropLife International (previously, European Crop Protection Association) guidelines for the formulation and packing of agrochemical products.

This plant has the same capabilities as our original facility, but has the following features –

Output of 20,000L/day achievable subject to analytical specification and formulation
Particle size reduction with Fryma colloid and bead milling using WAB KD280 Dyno Mill

Filtration & Heating

As complimentary processes to our standard bead milling and liquid blending procedures, we can filter and heat products to aid with product manufacture, or offer these as standalone services.

Filtration

Where materials contain oversized particles or contain impurities, we are able to employ a number of filtration techniques to ensure we meet the customer’s specification.

Mechanical filtration:

Can filter material down to a particle size of 50µm
Standard for suspension concentrate products
Both in-process and standalone capabilities

Bag Filtration:

Filter bags containing holes / mesh of the desired particle size to filter out contaminants – size between 1-1000µm
Ideal for emulsion concentrate formulated technicals and products containing low residual solids
Both in-process and standalone capabilities

Absolute filtration:

The go-to filtration method for when a precise and very low particle size is required
Filters material down to a particle size of 0.45µm
Both in-process and standalone capabilities

Heating and Cooling

Materials that we work with can often require heating to be manageable and worked with on the plant.

We have both a ATEX and non ATEX heating capacity
Products can be heated in the volume range of 10-8,000lts at a time
The possible heating range is from ambient to 105°c
Process heating / cooling – conducted via shell and tubing heat exchange