TARA IMPERIAL (PRIVATE) LIMITED

TARA GROUP PAKISTAN

INTERNSHIP REPORT

MUHAMMAD WAQAR

DEPARTMENT OF CHEMICAL ENGINEERING

COMSATS INSTITUTE OF INFORMATION

TECHNOLOGY, LAHORE

ACKNOWLEDGEMENTS

I would like to thank Ms. Fouzia Bano (Manager HR) & Mr. Mubashir Hayee Khan (GM Plant Operations) for giving me the opportunity to intern at Tara Imperial (Private) Limited (TIPL) & providing every possible extended support. Mr. Irfan Naseer Ahmad & Mr. Muhammad Akram for sharing their invaluable knowledge regarding process mechanisms & industrial practices. Mr. Sagheer Hussain & Mr. Nayaz Muhammad for on-site supervision & guidance regarding plant operations. All staff members & workers at TIPL whose courteous attitude & willingness to cooperate helped make it a thoroughly cherished & professionally rewarding experience.

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TABLE OF CONTENTS

COMPANY PROFILE 5

TARA GROUP PAKISTAN 6 TARA IMPERIAL INDUSTRIES (PVT) LIMITED 6 GROUP MISSION 6 GROUP VISION 7 PRODUCTS 7 CERTIFICATION & AWARDS 8 SWOT ANALYSIS 8 PLANT LAYOUT 9 OPERATIOAL OVERVIEW 11

CHEMISTRY OF THE PROCESS 12

PESTICIDES 13 TYPES & USES OF PESTICIDE FORMULATIONS 14 MICROFERTILIZERS 17 NUTRIENT SITUATION IN PAKISTAN 18 FERTILIZERS FORMULATIONS 18 KEY TERMS & DEFNITIONS 19

PESTICIDE FORMULATION PLANT 20

INTODUCTION 21 CAPACITY 21 RAW MATERIALS & PRODUCTS 21 PRODUCTION OF EC & SL 21 PRODUCTION OF SC, EW & SE 22 PFDs 23

GRANULE FORMULATION PLANT 25

INTODUCTION 26 CAPACITY 26 RAW MATERIALS & PRODUCTS 26 PRODUCTION OF WP & WDG 26 PFDs 27

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MICROFERTILIZER FORMULATION 28

INTRODUCTION 29 FORMULATION PROCEDURES 29

QUALITY CONTROL 31

INTRODUCTION 32 PESTICIDE TESTS 32 MICROFERTILIZER TESTS 33

SAFETY & HAZARD PROTECTION 34

AREAS OF CONCERN 35 PREVENTIVE & PROTECTIVE MEASURES 35

COMPANY PROFILE

6

TARA GROUP PAKISTAN

Tara Group Pakistan is one of the leading agro-chemical groups in Pakistan. It initiated its activities by setting up Flojo International in the year 2000. The Group activities gained its momentum by setup of Tara Packages Industries in the year 2008, an HDPE & PET bottle manufacturing unit which expanded to gravure printing, cartons and bags making to satisfy different market needs including Pharmaceuticals, Pesticides, Textile and Food industries. Tara Group Agro Division formally started off its operations in 2012 with the aim of manufacturing and supplying quality crop protection chemicals, micro fertilizers and certified seeds as well as providing solution to optimize farm productivity for farmer through high quality, innovative and cost effective products to provide the customer better value for money.

TARA IMPERIAL INDUSTRIES (PVT) LIMITED

Tara Imperial Industries (Pvt.) Ltd. located at located at Chunnia Bypass Road, Raiwind near Lahore, Pakistan comprises of the country’s most modern pesticide formulations plant equipped with state of the art equipment and highly trained staff. The technical dimensions and formulated/ finished goods and materials like micro-nutrients, fungicides and herbicides are being thoroughly analyzed. To assure the clientele, all packing materials go through a strict quality control procedure before being sent off into production line. This plant has an aggregate capacity of roughly 10 million bottles and 5 million units of powder and granule fillings. A large area has been put a side for the packing and storage of raw materials. All stores are equipped with automated loading and unloading facilities. Special training to the warehouse staff for chemical handling is also being provided. The staff is trained on ‘Workplace Safety Practices’ & all safety measures are in place to deal with any unfavorable incident. Tara Group Chemicals plant has a state of the art quality assurance laboratory which comprises of the worlds most modernized and superior instruments along with the highly experienced technical staff. For solvent based liquid formulations, the most-modern SL & EC formulations facility points are available. For SC formulations, a new state-of-the-art bead mills and a sheer mixer plant has been installed. All these are different types of formulations facilities i.e. powder formulations, granular formulations and liquid formulations. All these quality formulations would be utilized in the most efficient way so they could reach the hands of the end consumers in their original form. Tara Group takes this responsibility and hence ensures quality packaging and a filling facility.

GROUP MISSION

Manufacturing and supplying of quality crop protection chemicals, micro fertilizers and certified seeds. Providing solution to optimize farm productivity for farmer through high quality, innovative and cost effective products to provide the customer better value for money.

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GROUP VISION

To be leading organization by enhancing value to our customers, by caring for employees to work as a motivated team in an open and learning environment, setting challenging new standards of performance while focusing on total quality, innovation and responsible care towards society.

PRODUCTS

Pesticides Insecticides Herbicides Fungicides Granules Microfertilizers

Axona 10% SC Barko 80% WDG Brisbane 40% SC Check Worm 1.9% EC Coniflex 70% WS Coniflex 20% SL Coniflex 25% WP Cumix 10% EC Darwin 50% SC Deltamax 36% EC Durakill 2.5% EC Echophos 40% EC Emodox 9% SC Foxal 36% SC Jumper 2.5% EC Knocker 18% CF Lanolex 10.8% EC Latch 5% EC Macho Star 25% SL Orthox 75% SP Pyrizox 12.5% EC Pyrox Super 50% SG Rignil 5% SC Ripfos 44% EC Sega Pest Clear 3% SC Starfen 10% EC Super Lock 25% EC Telsta 20% SC Thomson 25% WDG Trix 80% SP Trofezon 25% WP Unifos 50% EC Vandol 22% ZC Vapco 20% SL Vapco 20% SP Wash Out 26% WDG

Atra Gold 96% EC Atracombi 80% WP Broxtra 40% EC Clean Core 50% EC Clover 20% WP G-max Lite 15% ECMaxtrol 38% SCMeture 30% SLMorcas 75% WGOne Shot 20% WPPendulum 33% ECPomaxtra 6.9% EWPrimechlor 60% ECRatol 70% WPShedder 20% SLShort Cut 48% SLShot Gun 37% ODSkype 15% WPStand Out 75% WDGUnimark 50% WP

Chlostrobin 56% SC Coopix 50% WP Court 80% WP Cytrol 75% WP Dora 25% EC Dora Max 50% WP Juliet 25% WP Polard 10% EW Rumble 32.5% SC Super Guard 72% WP Suprazole 52.5% SE Sweet Spot 80% WP Swing 72% WP Thiostar-M 70% WP Triseen 5% SL

Curan 3% G Riginil 0.4% G Tara Gold 5% G Tara Paidan 4% G

Extraphos 17:44 W/W Land Star 30% W/V Out-Look 20% W/V Reborn 10%+3.5% W/V Tara Fixer 5% W/V Tara Green 20:20:20 W/W Tara King 05:15:45 W/W Tara Phos 20% W/V Tara Root Feed 25% W/W Tara Super 08:08:06% W/V Tara Zinc 33% G, 21% G Tara Zinc 10% W/V Tri Power 15:0:30:20% W/W

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CERTIFICATIONS & AWARDS

Tara Imperial Chemicals holds the distinction of operating the only ISO/IEC 17025:2005 certified Pesticide & Micro-fertilizer testing laboratories in Pakistan.

Dr. Khalid Hameed, CEO, Tara Group Pakistan was named in the top 100 Best Performing CEOs & Companies of Pakistan 2016 by CEO Club, Pakistan & Manager Today

Fastest emerging agribusiness company in Pakistan. Business figures: 2.40 billion PKR (2013), 3.00 billion PKR (2014), 3.80 billion PKR (2015). An increase of 37% over two years. Target: 10 billion PKR by 2020.

SWOT ANALYSIS:

STRENGTHS WEAKNESSES

Experienced business personnel Existing distribution & sales networks Reduced labor costs Domestic market High growth rate

Limited production rates Developing organizational structure

OPPURTUNITIES THREATS

Growth rates and profitability Ongoing research & development New markets

Growing competition & lowerprofitability

Rising cost of raw materials External competition Financial capacity Tax changes Inelastic product demand

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TARA IMPERIAL INDUSTRIES PROJECT:-

TARA IMPERIAL INDUS.

DRAWN BY:-

Saqib AdnNls

DEUVERED TO:-

PROJECT DEPT.

SECTIONAL HEAD APPROVED BY:-

APPROVED BY:-

G.JI PLANT.

DATE:-

25-06-201

SCALE:-

N.T.S

CHUNNIA BYPASS ROAD, RAIWIND G.JI PLANT

DRAW/NC DETAIL:-

PLANT LAYOUT

CHECKED BY:-

GM

DRA-,,INC NO:-

TARA-ttf-Of3f

REVISION:-

003 UlR.PAKISTANE-MAIL: INFO@ TARAGROUP. COM.PK

Total Plant Area: 277,608 sq. ft. Total Covered Area: 64,248 sq. ft.

PLANT LAYOUT

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5

7

6

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10

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3

11

17 18 19

15 16

13 12 21

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Key:

1. Main Entrance2. Security Block3. Parking4. Mess and Prayer Area5. Administrative Block6. Fertilizer Testing Lab7. Pesticide Testing Lab8. Raw Material Storage9. WP / WDG Plant10. Micro-fertilizer Formulation Plant11. Pesticide Formulation Plant12. NPK Plant13. Urea-Phosphate Plant14. Utilities15. Powder Filling Hall16. Micro-fertilizer Filling Hall17. Bottle Filling Hall18. Finished Product Warehouse19. Packing Material Store20. Drum Storage Area21. Liquid Storage Area22. Water Reservoir23. Workshop

Accepted & Storage

Issuance ofRaw materials

Issuance of formulation recipes

from Quality Control Department

Formulation of Product by Mixing

and Blending

Quality Testing of formulated Product

Shifting to Filling /Packaging

Area

Drum Filling Filling / PackagingOperation

Receipt of all packing Materials

Dispatched to Market

Issuance ofPacking Materials RejectedImported

PROCESS CHEMISTRY

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PESTICIDES:

A pest is any troublesome animal, insect, plant, or disease that interferes with health, comfort, or productivity. A pesticide formulation is a mixture of active (pesticide) & inert ingredients (adjuvants, surfactants, stabilizers etc.) that are used to prevent, suppress or eradicate pests via direct or systemic contact with the pathogen. Some formulations are ready-to-use; others must be further diluted with water, a petroleum-based solvent, or air before they are applied.

Pesticides

Insecticides Herbicides Fungicides Rodenticides Bactericides Larvicides

Pesticides

Solid formulations

Ready-to-use (RTU)

Dusts (D)

Granules (G)

Concentrates

Wettable powders (WP)

Water DispersableGranules (WDG)

Soluble Powders (SP)

Liquid Formulations

Ready-to-use (RTU)

Ultra-Low Volume (ULV)

Concentrates

Suspension Concentrates (SC)

EmulsifiableConcentrates (EC)

Suspo-Emulsions (SE)

Solutions (S)

Vapor Flowables

Aerosols

Fumigants

Microencapsulates

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PESTICIDE FORMULATIONS:

1. DUSTS (RTU SOLID): Ready-to-use solid formulation that contains a low percentage of theactive ingredient plus a dry, inert carrier.Advantages: Ready-to-use, no mixing required, requires simple equipment, effective inhard-to-reach areas.Disadvantages: Drifts off-target, residues easily moved off target by air & rain, doesn’tstick as well as liquids, uneven distribution, irritates eyes, nose & throat.Uses: Used mainly to control indoor pests or seed treatment against Jasids, Aphids,Whitefly and Termites.

2. GRANULES (RTU SOLID): Ready-to-use, dry formulations prepared by applying liquidactive ingredient to coarse, absorptive material such as clay.Advantages: Particles settle quickly (low drift), little hazard to applicator, simpleapplication equipment, slow release of pesticide.Disadvantages: Don’t stick to foliage or surfaces, Need incorporation into soil to act,require moisture to activate, non-target wildlife may be affected.Uses: Effective against Leaf-folder, Enema-toads & diseases of Dead-heart & White-head.

3. WETTABLE POWDERS (SOLID CONCENTRATES): Ready-to-use, dry formulations preparedby applying liquid active ingredient to coarse, absorptive material such as clayAdvantages: Particles settle quickly (low drift), little hazard to applicator, simpleapplication equipment, slow release of pesticideDisadvantages: Do not stick to foliage or surfaces, may need to incorporate in soil andrequire moisture to activate pesticide, non-target wildlife may be affectedUses: Effective against Leaf-folder, Enema-toads & diseases of Dead-heart & White-head.

4. WETTABLE DISPERSIBLE GRANULES (SOLID CONCENTRATES): Active ingredient isprepared as dry, granular-sized particles. Granules are mixed with water, where theybreak into fine particles & form a suspension for application.Advantages: More easily measured and mixed than wettable powders, less inhalationhazard to mixers.Disadvantages: Requires constant agitation to keep the formulation in solution.Uses: Effective against Jasids, Aphids, Whitefly, Blackbug, Leaf folder in paddy crops.

5. SOLUBLE POWDERS (SOLID CONCENTRATES): Similar to wettable powder, but dissolvesreadily and forms a true solution. Few pesticides are available in this formulation.Advantages: Displays all of the advantages of wettable powders, non-abrasive to pumpsand nozzles, constant agitation not required.Disadvantages: Inhalation hazard during mixing.Uses: Effective against Thrips & Aphids.

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6. LOW-VOLUME & ULTRA-LOW VOLUME (RTU LIQUID): Very low or very highconcentration of Active IngredientAdvantages: No need for pre-mixing, the container also serves as the application device,delivery in the form of very tiny droplets provides excellent coverage.Disadvantages: Drift potential, dermal or inhalation problemsUses: Specialty situations (e.g., space spraying & fogging) small orchids, homes & offices.

7. SUSPENSION CONCENTRATES (LIQUID CONCENTRATES): Contains insoluble, finely-ground solid active ingredient mixed with a liquid (and inert ingredient) to form asuspension.Advantages: easy to handle and apply, seldom clogs nozzles.Disadvantages: Requires agitation and may leave a viable residue on surfaces.Uses: Effective against all types of caterpillars in all crops.

8. EMULSIFIABLE CONCENTRATES (LIQUID CONCENTRATES): Contains a liquid activeingredient, solvent and agent to allow formulation to mix with water to form an emulsion.Advantages: easy to handle, transport & store, little agitation required, nonabrasive, non-clogging, leaves little residue on surfaces.Disadvantages: Mixing & calibration required, toxic to plants & humans (easily absorbedthrough the skin), deteriorates equipment, flammable.Uses: Effective against mites, caterpillars, black bug, leaf mines in cotton, sugarcane &fruit orchids.

9. SUSPO-EMULSIONS (LIQUID CONCENTRATES): Suspo-Emulsions are mixtures of waterinsoluble active ingredients dispersed in an aqueous solution, where one or more of theA.I are in suspension and one or more of the A.I are in the emulsion. A suspo-emulsionformulation is essentially a mixture of a suspension concentrate with an oil-in-wateremulsion.Advantages: These mixed systems offer the benefit of a greater spectrum of pest controldue to mixed A.I. and typically eliminate the need for tank mixing. Their benefits includeease of mixing and handling, freedom from dust and water-miscibility.Disadvantages: Since they contain insoluble components they are not stable indefinitelyas are like ECs or MEs.Uses: Effective against blast, brown leaf spot, rust, powdery mildew, brown rot, blossomrot in orchids, sugarcane and wheat.

10. SOLUTIONS (LIQUID CONCENTRATES): Contains an active ingredient dissolved in a liquidsolvent (water or petroleum-based) usually concentrated but sometimes RTU formulated.Advantages: No agitation needed.Disadvantages: A limited number of formulations of this type available.Uses: Effective against citrus-canker, rizoketonia, stem-burning in orchids & crops.

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11. AEROSOLS (VAPOR FLOWABLES): Contains one or more active ingredients and solvent(usually petroleum distillate); packaged in a ready-to-use pressurized container or applied in a smoke or fog generator.Advantages: Convenient. The user can purchase small quantities of pesticide. Easilystored and does not lose activity.Disadvantages: Limited usage. Difficult to confine to target site or pest therefore risk ofinhalation injury.Uses: Space spraying. Crack & crevice treatments for structural & household pest control.

12. FUMIGANTS (VAPOR FLOWABLES): Pesticides that form poisonous gases when applied.Formulated as liquids or solids. Can be released under pressure, high humidity or watervapor.Advantages: Toxic to wide range of pests. Can penetrate very small areas. Usually requiresa single treatment.Disadvantages: Highly toxic to humans & non-target organisms. Requires use ofspecialized application equipment & protective equipment (respirator). The treatmentarea must be enclosed or covered.Uses: Greenhouses, bins, structural disease control. Regulatory pest control at ports orborders.

13. MICROENCAPSULATES (VAPOR FLOWABLES): Particles of pesticide active ingredient(liquid or dry) surrounded in a plastic coating. Formulated product is mixed with waterand applied as spray. Following application the capsule slowly releases the pesticide viavarious payload release mechanisms such as:

• Enzymatic Digestion (erosion)• Diffusion• Membrane Dissolution (Chemical Change)• Mechanical Fracturing (due to pressure changes)• Freeze Fracturing (due to temperature change)

Advantages: Increased safety to applicator so can be used for highly toxic substances. Easy to mix, handle & apply. Slow release of pesticide. Provide longer residual protection without leaving residue. Disadvantages: Constant agitation required. Bees may pick capsules & take back to their hives. Expensive in low volumes. Uses: Greenhouses, bins, structural disease control. Regulatory pest control at ports or borders.

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MICROFERTILIZERS:

A fertilizer is any material of natural or synthetic origin, solid or liquid that is applied to soils or to plant tissues (usually leaves) to supply one or more plant nutrients essential to the growth of plants. Fertilizers are either administered through soil (with water) or through leaves (foliar feeding)

• There are three primary macronutrients: Nitrogen (N), Phosphorus (P), Potassium (K)• Three secondary macronutrients: calcium (Ca), magnesium (Mg), and sulfur (S);• Micronutrients: copper (Cu), iron (Fe), manganese (Mn), molybdenum (Mo), zinc (Zn), b

oron (B), and of occasional significance there are silicon (Si), cobalt (Co), & vanadium (V)plus rare mineral catalysts.

Fertilizers may also be divided on basis of:

• Single nutrient fertilizers: Provide a single nutrient in large quantities. The main nitrogen-based straight fertilizer is ammonia or its solutions such as Ammonium nitrate (NH4NO3).Urea is another popular source of nitrogen, having the advantage that it is a solid & non-explosive. The main straight phosphate fertilizers are the Superphosphates. Singlesuperphosphate (SSP) consists of 14–18% P2O5. Triple superphosphate (TSP) typicallyconsists of 44-48% of P2O5. A mixture of SSP & TSP is called double superphosphate (DSP).More than 90% of a typical superphosphate fertilizer is water-soluble. Potassium isusually administered as Sulfate of Potash (SOP) & Merite of Potash (MOP) which are K2S& KCl respectively. Also as K2NO3.

• Multi-nutrient fertilizers: They consist of two or more nutrient components & can befurther divided into:

o Binary (NP, NK, PK) fertilizerso NPK fertilizers

Binary fertilizers provide both nitrogen & phosphorus to the plants. Major binary fertilizers are mono-ammonium phosphate (MAP) & di-ammonium phosphate (DAP). About 85% of MAP and DAP fertilizers are soluble in water. NPK fertilizers are 3-component fertilizers providing nitrogen, phosphorus & potassium. NPK rating is a system describing the amount of each of these elements or their compounds in a fertilizer. Example: 10:10:10 or 16:4:8. The first number represents the percentage of nitrogen or its compound in the product while the second & third represent similar content for Phosphorous & Potassium respectively.

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NUTRIENT SITUATION IN PAKISTAN

• Nitrogen & Phosphorus: Extremely low levels.• Potassium: Low in patches. Downward trend due to high consumption• Magnesium: Deficient in patches• Sulfur: Deficient in northern regions, not in plains or south• Zinc: Overall deficiency• Iron: Recently deficient• Manganese: Limited deficiency. Not overall deficient• Boron: Deficient but difficult to plot on scale due to close extremes• Calcium, Molybdenum & Copper: No deficiency.

FERTILIZER FORMULATIONS

• NPK Combos (% of pure element): 20:20:20 (solid). 5:15:45 (solid). 8:8:6 (liquid foliar)• NKS Combo: 15:30:20 (solid)• Nitrogen: 20% (liquid foliar)• Potassium: 30% (liquid foliar)• Urea Phosphate: 17:44 (Solid)• Potassium: Sulfate of Potash 30% (liquid)• Micronutrient combo (Zn, Fe, Mn & Cu): 7:1:1:1 (liquid foliar)• Zinc: 33% & 21% as ZnSO4 (solid). 10% (liquid).• Boron: 5% (foliar liquid).• Humic Acid (Mixture of lignite coal & KOH): 10% (liquid). 47% (solid land mix).

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KEY TERMS & DEFINITIONS

• Active Ingredient: Chemical that controls target pest and has toxicity.• Adjuvant: Chemical that is either premixed in the pesticide formulation or added to the

spray tank to improve mixing, application or to enhance pesticide activity. These Includebuffers, surfactants, stickers, stabilizers, stickers, spreaders, thickeners, co-solvents,wetting agents etc.

• Carrier: Primary material such as water, air or oil used for effective pesticide dispersal• De-foaming Agents: Prevent foam formation in spray tanks• Drift: Airborne movement of pesticide away from release site.• Emulsifier: Helps prevent emulsion from separating & ensures equal distribution

throughout the solvent• Emulsion: Mixture of two or more liquids that are not soluble in one another; one is

suspended as small droplets in the other.• Raw: Unformulated state of Active Ingredient• Stickers: Increase adhesion of solid particles to target surface• Surfactants: Alter surface tension of spray droplets increasing its reach over plant surface• Technical: Term used by most of the agrochemical industries, particularly those industries

that are directly concerned with formulation, for the main reactant involved in particularprocess.

• Thickeners: Increase viscosity of formulates decreasing evaporation rate• ULV (ultra-low-volume): Concentrations that approach 100% active ingredient.

PESTICIDE FORMULATION PLANT

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INTRODUCTION:

The formulation plant mainly deals with the production of liquid phase pesticides via batch process. The plant is equipped with the best process & quality control instrumentation.

CAPACITY:

EC & SL Formulation: 80,000 liters/day SC Formulation: 24,000 liters/day

RAW MATERIAL FOR PESTICIDES: PRODUCTS:

Technical (Active Ingredient) Emulsifiable Concetrate (EC) Emulsifier (Surfactant) Soluble Liquid (SL) Xylene or R.O Water (Solvent) Soluble Concentrate (SC)

Emulsion in Water (EW) Soluble-Emulsion (SE)

PRODUCTION OF EMULSIFIABLE CONCENTRATE (EC) & SOLUBLE LIQUID (SL):

1. The raw material (technical & emulsifier) is preheated in hot water bath up to its flowable temperature.

2. All concerned valves and gauges are checked.3. 60% by weight of solvent, Xylene, from storage tank is charged into the reacting tanks.4. Weighed quantities of technical & emulsifier are added while continually stirring. For

safety purpose nitrogen is charged to the tank, it forms a layer at the top which reducesthe chance of fire. If the technical is in powder form then it is charged from the top inletof the reacting tank. Liquid technical is charged from the charging sections with the air-driven pneumatic pump.

5. Required residence time, 30 minutes, is provided to the mixture in the reacting tank withcontinuous agitation

6. During the agitation sample is taken from the reacting tank with help of a small cylinderattached to rod. This sample is then sent to the laboratory for its final quality test and asit is approved the batch is then transfer to the holding tanks using centrifugal pump.

7. Before the transfer, the batch is allowed to settle for few minutes. This settles the slug atthe bottom of tank if present.

8. The slug is removed and the product is transferred to the holding tanks. Cycle time ofbatch is nearly 1 hour and 30 minutes.

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PRODUCTION OF SOLUBLE CONCENTRATE (SC), EMULSION-IN-WATER (EW) & SOLUBLE-EMULSION (SE):

1. The raw material (emulsifier) is preheated in hot water bath. The technical being used forEW, SC and SE is mostly in form of fine powder. Solvent used here is Reverse Osmosiswater

2. All the concerned valves and gauges are checked.3. Weighed amount of Reverse osmosis water from storage tank is charged into the reacting

tanks4. Weighed amount of specific Technical is charged carefully and slowly into the reacting

tank.5. Required emulsifier is charged from the charging section using the air-driven diaphragm

pump. Solvent (reverse osmosis water) is added for overall balance.6. Required residence time, 30 minutes, is provided to the mixture in the reacting tank.

Additional steps for SOLUBLE CONCENTRATE (SC) formulation

7. The circulation pipeline involves a shearing pump, which applies shearing force to thetechnical and makes the size finer and does mixing.

8. After an hour, the shearing pump is switched off and then the mixture is circulated inanother pipe line which involves bead mill.

9. Bead mill contains small beads which help to reduce the product size to <1ųm10. After the size approval, 1200kg of slurry at 50C from another reacting tank is charged to

the main reacting tank.11. Then again after charging slurry the shearing pump is turned on for half an hour.12. Here the product is not transferred to the holding tanks but direct filling of drum is done.13. Cycle time of batch is nearly 1 hour and 15 minutes.

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Centrifugal pump

Shell and tubeHeat exchanger

Furnace

FurnaceOil in

Xylene Storage tanks

Furnace oil out

DirtyWater in

Carbon tank

Cartridge filterMembrane Filter

Reverse Osmosis Plant

Storage

Cold Water in

HotWaterOut

Hot water bath

Nitrogen cyclinder

Motor

DCP

SideMirror

Centrifugalpump

HotWater

in

Water out

Bi-pass

SampleValve

Double-diaphragm pump

To RT-1

To RT-2

To RT-3

To RT-4

Raw Material

(Emulsifier, Technical)

DCP

Nitrogen cylinderexhaust

exhaust

For packing

Product

Reacting tank-1

StrainerSide

Mirror

circulating

Flushing line

Holding tank-1

To holdingTank-2

Pre-formulated

Product

PFD - EC & SL Formulation

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Furnace

FurnaceOil in

DirtyWater

in

Carbon tank

Cartridge filter

Membrane Filter

Reverse Osmosis Plant

Storage

HotWaterOut

water bath

Nitrogencylinder

DCP

SideMirror

Shearing pump

HotWater

in

Cold Water

out

To RT-6

Raw Material (Emulsifier,Reverse

osmosis water)

Double Diaphragm

pump

Circulating line

ColdWater

in

Hot water out

To RT-5

Furnace oil out

Water in

SideMirror

exhaust

SampleValve

Product

Reaction tank-6

Reaction tank-5

BeadMill

PFD - SC, EW & SE Formulation

GRANULE FORMATION PLANT

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INTRODUCTION:

The plant was established with the aim of producing insecticides in granule form via continuous process. The plant is equipped with the best process & quality control instrumentation. Sticker solution is a mixture of a different chemical compounds that is used to stick the granules on their support (e.g. silica). Each product has its own sticker solution for effective hold

CAPACITY

WP Formulation: 20,000 kg/day Granules Formulation: 50,000 kg/day

RAW MATERIALS: PRODUCTS:

Technical (Active Ingredient) Wettable Powders (WP) Fillers Wettable Dispersible Granules (WDG) Emulsifier Additives (Sticker Solution)

PRODUCTION OF WETTABLE POWDERS (WP) & WETTABLE DISPERSIBLE GRANULES (WDG):

1. 50% of total Filler by weight is loaded into the main mixer2. 25% of total Filler by weight is mixed with 50% of Technical by weight and Additives. This

concoction is added to the main mixer.3. Remaining 25% of total Filler by weight is mixed with Emulsifier & added to the main mixer4. The main mixer is set into agitated operation for 30 minutes at 3000rpm & 7 bar5. The output from the main mixer is sent to the first cone mixer where product size

distribution is narrowed down. This is checked by taking a sample & performing a wetsieve test

6. The output from the first cone mixer is sent to a cyclone mixer where dust is separated7. It is then re-agitated in a second cone mixer for 2 to 3 hours8. The output from the second cone mixer is sent to a ribbon mixer for 30 minutes. Here

cooling of the mixture takes place and assumes wet powder form.9. For WP Formulation the powder is passed through kneader mixers where wet kneading

takes place & WP noodles are formed. These are dried.10. For WDG Formulation the powder is passed through granule machine (detail below) to

form granules which are dried.11. Moisture & size distribution tests take place & the approved product is packed.

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MICROFERTILIZER FORMULATION

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INTRODUCTION:

Methods of fertilizer formulation can be divide into two categories according to the process of manufacture as follows:

• Multi-component mixed fertilizers. These are manufactured by mechanical mixing ofone-component fertilizers and are either in powder or granulated form.

• Combined fertilizers. These are manufactured by chemical processes of the original rawmaterial.

Powder fertilizers have a grain size of less than 1mm while granular fertilizers have a grain size of between 1 & 4 mm. Liquid Fertilizers can again be straight or compound, are produced as clear solutions or suspensions and may be subdivided into inorganic fertilizers liquid - pressure-free, high and low pressure.

FORMULATION PROCEDURES:

HUMIC ACID 10% & 47%

Sodium or Potassium Hydroxide are reacted with humic acid in a batch reactor with a residence time of 1-1.5 hours. The complex formed at the end is known as Sodium/Potassium Humate

POTASH 30%

Phosphoric Acid & Potassium Carbonate are reacted in a heated-coil batch reactor between 70C to 90C. Potassium di-hydrogen phosphate is formed which is dried & made oil free before being stored or packed.

UREA PHOSPHATE

Urea is added to Phosphoric Acid at temperatures exceeding 80C. Urea Phosphate crystals are formed when the product is dried to less than 2% moisture

NPK 20:20:20 & NPK 5:15:45 & NPK 8:8:6

Ground nitrogen is added to crystal mixture of potassium di-hydrogen phosphate. Sieving is done to ensure uniform composition

NKS

Mixture of urea, di-ammonium sulfate & potassium sulfate/potassium chloride

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PHOSPHATE 20%

Dilution of phosphoric acid. Urea phosphate is formed as a residue

POTASSIUM SULFATE (SULFATE OF POTASH, SOP)

Potassium carbonate is reacted with sulfuric acid to form SOP. CO2 also formed

ZINC SULFATE 33%, ZINC 10%, ZINC 21%

All formed by dilution of pure zinc sulfate in water

BORON 5%

Dilution of boric acid

QUALITY CONTROL

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INTRODUCTION

Quality Assurance (QA) is an integral aspect of manufacturing. From raw materials to packed products QA ensures that the internal or external factors present, do not affect the required product at any part of the process and that the final product must comply with set standards. In this regard sampling is done at different parts along the production line from raw material storage right through to packaging area. These samples are tested in specific, well-equipped laboratories & any glitches are promptly identified & corrected in accordance with the test results. The final product is released into the market only after ensuring that all performed tests yielded required results & that the required product standards have been met.

PESTICIDE TESTS

• Active Ingredients (A.I): High Performance Liquid Chromatography (HPLC) & GasChromatography are used to test for A.I. No physical/manual tests are performed for A.Idetection.

• Wetting Time: A weighed amount of the powder is dropped on water in a beaker from aspecified height. The time for complete wetting is determined.

• Wet Sieve Analysis: Sieve analysis consists of the quantitative separation of a powder intofractions with different ranges of particle size by use of an appropriate sieve or sieves.Sieving is carried out by washing the material on the sieve with a stream of water.Treatment of the sample with a wetting agent is used, where necessary, to assist thesieving process. Where more than one nominal aperture size is specified, the sample isfirst sieved on the smallest aperture sieve. This removes most of the very fine particleswhich tend to clog the sieves and may interfere with quantitative separation of the largerparticles. The sieves are stacked in order of aperture size with the largest at the top; theretained material is transferred to the largest aperture sieve, and sieving continued untilpassage of undersize material through each sieve is substantially complete. The residueon each sieve is finally transferred to a dish, dried and weighed.

• Suspensibility: Suspensibility is defined as the amount of active ingredient suspendedafter a given time in a column of liquid, of stated height, expressed as a percentage of theamount of active ingredient in the original suspension. A suspension of knownconcentration in Standard Water or distilled water is prepared, placed in a prescribedmeasuring cylinder at a constant temperature, and allowed to remain undisturbed for thespecified time. The top 9/10ths are drawn off and the content of active ingredient in thebottom 1/10th determined, so allowing the content of the top 9/10th to be calculated.

• Density/Specific Gravity: In this method the weights of equal volumes or the materialand water are compared. The method is suitable for the determination of the specificgravity or density of liquids or solids. It is not suitable for these determinations on highlyvolatile liquids.

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• Solubility: The solubility - within predefined ranges - of a test substance in organicsolvents is determined by adding measured volumes of solvent to a known mass of testsubstance until complete dissolution is observed. A preliminary test is employed todetermine the approximate solubility of the test substance. The results of the preliminarytest are used to select the most appropriate mass of test substance for the test.

• Particle Size: A representative sample, dispersed at an adequate concentration in asuitable liquid or gas, is passed through the beam of a monochromatic light source,usually a laser. The light scattered (laser diffraction) by the particles at various angles ismeasured by a multi-element detector and numerical values relating to the scatteringpattern are then recorded for subsequent analysis. These numerical scattering values arethen transformed, using an appropriate optical model and mathematical procedure, toyield the proportion of total volume to a discrete number of size classes forming avolumetric particle size distribution.

• Viscosity: This method determines the viscosity of an oil as a time of flow in secondsthrough a Redwood viscometer.

• Emulsivity: An emulsion of known concentration in standard water is prepared. Thestability of this emulsion is then assessed in terms of amounts of free 'oil' and/or 'cream',which separates while the emulsion is allowed to stand undisturbed for 24 h. The abilityof the system to re-emulsify at the end of the 24 h period is also determined.

MICRO-FERTILIZER TESTS:

• Color: Visual comparison with prepared solutions• Moisture (for solids): Heat sampling by placing in a crucible in oven at 105C for 2 hours &

noting change in weight• Density (for liquids): weight by volume = density

SAFETY & HAZARD PROTECTION

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AREAS OF CONCERN:

• Toxic, explosive, inflammable &/or oxidizing substances• Dust Hazard• Leakage or Bursting of Pressurized Vessels• On-site Injuries/Accidents• Design Defects• Instrumentation Failures

PREVENTIVE & PROTECTIVE MEASURES:

• Safety Training at orientation for new employees & regular Safety Drills for currentemployees. Safe practices are mandatory for all persons within plant premises at all times.

• Use of protective gear including shoes, masks, gloves, googles, caps & gowns mandatorywhere required. No loose fitting clothing allowed

• Periodic maintenance & checking of all instruments, vessels & utilities.• Necessary hazard/safety warnings & emergency escape routes are well-marked.• For electrical installations and instrumentation, the entire plant area has been sub divided

into hazardous and non-hazardous zones. The hazardous zones have been classifiedappropriately as per the National Fire Protection Association (NFPA) code 70, betterknown as the National Electric Code. The NFPA classifies Hazardous Areas by threedifferent factors known as classes, groups and divisions. These factors each identifydifferent elements of concern and combine to define the type (Class) & explosive rating(Group) of the hazardous substance and the degree of hazard created (Division) by it.

• Distance is maintained in protection zones as per rules. The equipment, piping &instruments are provided for explosion protection & non-explosive materials are used.

• Factory premises are strictly maintained as ‘No Smoking Zone’. Designated safe spots areprovided for smokers. The plant is well equipped with all Fire Safety appliances like FireTenders and different types of fire extinguishers like DCP, CO2, water, foam types inadequate numbers. Well-laid system of underground piping is provided with outputslocated throughout the plant. Fire Alarm & Smoke Detection system for plant, controlrooms, administrative buildings and laboratories is also provided. These are of Ionization,Optical & Heat sensing type. All Xylene tanks are protected by installation of automaticfixed foam pouring system at their top which is checked periodically and record ismaintained.

• The plant layout has been designed as per established engineering practices, inconformity with the provisions of required safety rules. The layout of plant, under thepurview of the various statutory regulations has been granted and these regulations arerenewed regularly.