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New report profiles latest crop protection formulations
and technological developments
IHS Markit Crop Science's Formulations 2020 is
concerned with the formulation of crop protection products, in
particular the features of the commercially important formulation
types in the market. We also examine the products and companies
active in formulation in this market and review the latest
technological developments via the available patent and academic
literature.
To learn more about crop formulations and technological
developemnts take a look at our short video presentation below.
In Chapter One "Introduction to Crop Protection Products
and their Formulation", we define the scope of the report
and of formulation itself. We also summarise the objectives of
formulation and briefly introduce the main formulation types used
for crop protection products. We summarise the trends in the market
which have an impact on developments in formulation before
providing a summary of some main points from the previous report in
this series (2016) as well as of the significant changes which have
taken place since its publication.
The global market for conventional crop protection products
(excluding sales of herbicide tolerant and insect resistant seed,
as well as non-crop agrochemicals) is estimated to have decreased
marginally, falling by 0.8% in 2019 to $59,827 million; when
measured in real terms (excluding the impact of inflation and
currency factors) the overall market is estimated to have
experienced a more significant decrease, down by 5.8% on the
previous year. This figure is based on the results of our own PMD
market analysis of the crop protection sector and takes into
account the results of market research conducted in the majority of
country markets.
In 2019, weather played the most significant part in influencing
the global agrochemical market with extremes from severe flooding
in North America to dry conditions and drought across major areas
of Europe and Asia Pacific, equally detrimental to demand of crop
protection products. In addition, tensions between the governments
of the USA and China also shifted global trade patterns, with China
replacing US produce, particularly soybeans, with those from Latin
American countries. Other factors limiting prospects for the 2019
agrochemical market include increasing regulatory pressures in
Europe leading to the ban of notable chemistries and strength in
the US dollar, which limited growth potential elsewhere.
On a more positive note, and somewhat offsetting the declines
outlined above were the continued high pricing levels for generic
products, particularly those emanating from Chinese manufacturers;
further growth in Latin America in response to normalised inventory
levels; as well as increasing adoption of alternative GM traits,
shifting demand away from glyphosate tolerance and into newer and
more expensive herbicide technologies such as glufosinate, dicamba
and 2,4-D.
As for non-crop agrochemicals, the market is estimated to have
grown by around 3.5%, largely in line with global GDP growth. This
market can continue to grow in the coming years boosted by
improving economies in developing nations.
Chapter Two is entitled "Formulation Types: Overview and
Applications". A very wide variety of formulation types
are available to the formulator to choose from when designing and
developing new formulations. Apart from regulatory considerations,
the most important factors which the formulator must consider at
the start of development are the intended application method as
well as the physical and chemical properties of the active
ingredient. These two factors alone are likely narrow the possible
formulation types to a manageable number for further consideration.
Further factors will then come into play including costs,
availability of manufacturing assets, packaging compatibility,
safety and environmental protection.
Once the preferred formulation type has been chosen and
development has begun, the formulators key challenges are likely to
be related to optimising the stability of the formulation and
maintaining the target efficacy under application conditions. The
processing equipment for manufacture will need to be chosen and
laboratory conditions will have to be scaled up. Other application
properties that also need to be considered include product
redispersibility and flow properties. The main choices at this
stage will be which co-formulants to use and which processing
conditions should be used.
Regulatory considerations and restrictions have to be considered
at all stages of the process. Restrictions may include limitations
or prohibition of certain formulants and regulators are likely to
require a comprehensive dossier detailing the properties of the
final formulation.
In Chapter Three "Formulation Types: Market
View", we focus on the relative significance of the
different formulation types in the market and detail the most
significant formulation types by value and by volume. The most
significant formulation types by value in the crop protection
market are SC (suspension concentrate), EC (emulsifiable
concentrate), SL (soluble liquid concentrate), WG (water
dispersible granule) and WP (wettable powder).
Measured by volume, SL formulations are relatively more
significant and WG and WP formulations less so. This is due to the
relatively high AI strength (and unit price) of WG and WP
formulations and to the importance of glyphosate and other
herbicides formulated as relatively low-cost SL formulations. SL
and EC formulations are the most important formulation types for
herbicides, whereas SC and EC dominate for value by fungicides and
insecticides.
In Chapter Four we take a close look at emulsifiable
concentrate (EC) formulations. Emulsifiable concentrates
are a popular format with significant sales in all pesticide fields
of use. Although their demise has been predicted for a while, there
is no evidence that their market share will reduce for quite some
time. There are moves to look for newer solvent systems but
aromatic solvents still appear in both literature and newer
patents.
Mixtures of actives are the subject of much interest both
commercial and academic and this is leading to an increase in
complexity of the formulation. Whilst there is some evidence of
research looking to move actives and their mixtures away from the
format, there are also examples where its' simplicity in
manufacture and reduced costs can lead to movement from more
complicated systems such as capsule suspensions.
In Chapter Five we move on to suspension concentrate
(SC) formulations. Suspension concentrates are a popular
format with significant sales in all pesticide fields of use. Due
to being water based, the format will be a preferred choice when
starting a development programme with a new active, so long as the
properties of the active ingredient are suitable (i.e. low water
stability and melting point greater than room temperature).
As with other formulations much activity is focussed on blends
of actives and the formulation technology associated with this. The
most factor to consider when formulating for stability is the
choice and level of dispersant. Academic literature and patent
activity are dominated by China.
Chapter Six takes a look at another popular format,
soluble liquids (SL). Despite the apparent simplicity of
the formulation, Soluble Liquids (SL) are one of the most
significant commercial formulation types. They are dominated by
herbicides and the major actives such as glyphosate, glufosinate,
dicamba, and 2,4-D. Due to being water based, the format will be a
preferred choice when starting a development programme with a new
active, so long as the properties of the active ingredient are
suitable (i.e. high solubility and hydrolytic stability).
In terms of formulation, the salt type is key to achieving the
high active content required in commercial formulations and this
can also aid with other properties such as minimising spray drift.
This function (spray drift control) is very topical at present and
the subject of much debate, particularly in the US. Other
formulation additives included in formulations are surfactants and
adjuvants to aid with leaf wetting and penetration.
As with other formulations there is much activity is focussed on
blends of actives and the formulation technology associated with
this. With the high-profile actives in this format, the formulation
impact on toxicity and the environment is becoming more critical.
Patent and academic activity is not necessarily focussed on the
formulation type but more on the active ingredients.
Chapter Seven is a round-up of the other liquid
formulation types in the market. In most liquid
formulations, herbicides tend to dominate in terms of value and
this applies to most of the relatively niche formulation types
discussed in this chapter. Those described in this chapter are
often regarded as problem solving formulations and although of real
scientific interest are often regarded as a "last resort" choice
for the formulator. They all, however, have common functionalities
in that beside the active(s), they have a continuous medium,
stabilisers (surfactants and/or rheology modifiers) and adjuvants
to help with application properties.
With increasing challenges from pest resistance and regulators
to prevent worker and environmental exposure, we will however see
these types increasing in importance but the technical challenge
and regulatory costs should not be underestimated.
In Chapter Eight we move onto the solid formulation
types and look at wettable powder (WP) formulations.
Wettable powder (WP) formulations are relatively simple and
cost-effective options which are especially suitable for active
ingredients (AIs) which are high melting and water-insoluble
solids. Their main disadvantage is that they can generate dust
which can be an inhalation hazard. WP formulations are seen across
all fields of use (fungicides, herbicides, insecticides and
acaricides) with fungicides accounting for over 40% by value of WP
formulated products. A number of significant commodity AIs can be
formulated as WP, including carbendazim, mancozeb, imidacloprid and
bensulfuron. As well as the AI, WP formulations contain fillers,
dispersing agents, wetting agents and flow aids. Innovation
activity on WP formulations in the last four years has been modest.
Comparisons of WP with other formulation types has shown both
advantages and disadvantages, depending on both the AI and the
application. Only a small number of patents showing innovation in
WP formulation have been found. These patents mainly cover
biological AIs, where WP is still a common format.
Chapter Nine examines another very significant solid
formulation type, water dispersible granules (WG). These
are popular formulations which are convenient with good handling
properties and safety benefits. Against these benefits must be set
the relatively high cost and complexity of producing them.
Nevertheless, a wide variety of AIs on the market are produced in
the WG format which accounts for about 12% of the crop protection
market by value. Around half of WG products by value are herbicides
and over 30% by value are herbicides. In contrast to the WP format
which is mainly used for lower value generic AIs, WG is used widely
for patented specialities and generics alike. WG formulations can
be manufactured at a high AI strength and dispersing agents,
wetting agents, disintegrants and fillers are the main
co-formulants used.
The innovation level (in terms of numbers of academic and patent
publications) in WG formulations appears to be quite low,
indicating that it is a well-established and largely optimised
format.
In Chapter Ten we consider granules for dry application
(GR). These formulations are relatively simple and cost
effective to make using relatively unsophisticated equipment. Their
large particles don't drift when applied and the products don't, in
general, generate harmful dust. The ability to provide controlled
release properties is a major benefit which can possibly extend the
lifetime of the application and reduce overall environmental
exposure. The main application by some distance is for rice paddies
in Asia where mixed functionality (e.g. insecticide plus fungicide)
is often desired, so there are many mixture products containing
multiple AIs. Herbicides for rice paddies are also a significant
area. Granules can also be applied dry to soil or furrows in which
case disintegration properties are important.
There is a moderate amount of innovation in granule
formulations, with controlled release properties being the main
focus of both academic research and patent applications. A number
of such formulations have been commercialised.
Chapter Eleven covers all of the other solid formulation
types on the market. There is a wide range of "minor"
solid formulation types available for both direct (dry) and spray
tank application. The most important of these are dustable powders
(DP), soluble powders (SP), soluble granules (SG) and tablets (TB).
Soluble granules are analogous to water dispersible granule (WG)
formulations with the difference being that in SG products the
active ingredient is water soluble and so forms a true solution
rather than a dispersion. Likewise, SP formulations are similar in
form and use to wettable powder (WP) formulations. Dustable powders
are used for direct application, often aerial (crop dusting).
Sulphur is a common fungicide which is formulated as DP.
There is a relatively small amount of patent or academic
literature in the field of these minor types, which is consistent
with their value in the market.
In Chapter Twelve, "Special Topic: Biocontrol
Formulations", we examine a commercially fast-growing
topic. The market for biocontrol agents is expected to grow
considerably over the foreseeable future. A key element in
continuing this growth will be the global regulatory procedures
relating to the approval of biocontrol products. As individual
actives are often very specific, then the market can be small in
comparison to more conventional pesticide actives and therefore the
regulatory costs are even more significant in making the business
case to commercialise a biocontrol product.
Whilst the "Holy Grail" for those developing and promoting the
use of biocontrol products is the complete replacement of chemical
pesticides, this is unlikely to occur in the short to medium term
and there are signs within the market that the combination of
biocontrol products with more conventional products is gaining
traction. For commercial reasons, recognising the
threat/opportunity from biocontrol products some of the major
chemical pesticide producers have started to promote combined
treatments. As well as these combination products we are expecting
to see more regulation, better use of adjuvants and co-formulants
and an alignment to the other drivers of smart agriculture.
Formulation will be key to meeting growth expectations and will
follow mainly the same path as that for conventional plant
protection products with the exception that the changes are likely
to be much quicker.
Chapter Thirteen takes a look at another special topic,
that of seed treatment formulations. There are a large
number of potential seed treatment formulation types but DS (dry
powder), WS (water dispersible powder), LS (liquid solution) and FS
(flowable concentrate) are the most commercially important types.
The formulations of these closely resemble the mainstream crop
protection formulations described elsewhere this report, i.e. WP,
WP, SL and SC. Most synthetic actives formulated as seed treatments
are either insecticides or fungicides. Formulants used in seed
treatments also resemble those used in mainstream crop protection
formulations, e.g. anionic and non-ionic surfactants, glycol
antifreeze/humectants, mineral carriers/fillers and oily
stickers.
There is a moderate amount of innovation activity as evidenced
by patents and other publications and this appears to be focused
mainly on formulations of biocontrol actives (mainly microbials)
and combinations of these with synthetic actives. Biostimulant and
nutrient formulations are also represented. There is also a steady
series of innovations in the area of novel formulants (e.g.
polymers, rheology modifiers, fillers) for seed treatments. Novel
methods such as encapsulation have also been described.
Chapter Fourteen consists of a review of the main
companies involved in crop protection formulation, whether
as producers of formulated products or as members of the supply
chain providing co-formulants or services. The major crop
protection companies all maintain a high level of capability in
formulation. The products launched appear in most of the main
formulation types although liquids (especially SC and EC) appear to
dominate.
The supply chain for formulation includes the specialty
chemicals divisions of many diversified multinational chemical
companies as well as a number of smaller players. Although
formulants such as surfactants and rheology modifiers can be used
in many different industries, it is significant that a number of
these suppliers do highlight their use in agrochemicals and offer
expertise and recommendations specifically for formulators in those
markets. The supply chain for formulation is also populated by a
large number of service providers, in particular contract
manufacturing companies but also by companies providing laboratory
formulation development services. There is no sign of these service
providers reducing in number in recent years which indicates the
demand for outsourced services remains strong.
In the final chapter, we take a brief look into the
future to comment on trends in formulation and where they could
lead. It is to be expected that many of today's market
trends and drivers will continue to be important in future years.
In particular drivers relating to regulations, environmental
acceptability and safety will remain strong. These drivers will
result in incremental changes of the sort we are already familiar
with. On the other hand, the potential for the most radical changes
in the way pesticides are used (and which could have an impact on
the way they are formulated) is likely to come from disruptive
technologies which are already starting to be applied in and
outside the field of agriculture. Exactly what this means for
agrochemical formulation remains to be seen but most of these
developments would move the market towards more customisation of
products, smaller volumes, robust and concentrated formulations,
higher flexibility and more precision - and away from traditional
bulk volume spray tank application. In particular, there is
exciting potential in emerging technologies that can:
• Integrate sensors, data management and artificial
intelligence;
• Deploy precision application via automation and robotics;
• Make use of better understanding of biological and in
particular genetic mechanisms.
Other more disruptive approaches may arise from within the
industry itself such as microwaves and lasers that can be used to
destroy pests without the use of pesticides, or "vertical farming"
approaches that would allow crops to be grow without pesticides, or
with much lower amounts. That companies involved in agriculture are
prepared to invest in novel approaches is evidenced by venture
investment decisions.
About the Authors
iFormulate (www.iformulate.biz) was founded to
provide customised R&D and innovation services to companies
working in the field of Formulation Science and Technology. They
offer consultancy, project management, idea generation and
development, assistance with commercialisation, market and business
development, training and events. They have written several
previous reports for IHS Markit Crop Science (Agrow) including
Bioformulations and Sustainability in
Agrochemicals.