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Insecticides manufacturing process is a complex set of multiple sub-processes.

From the raw material preparation to the final stage of packaging and shipping, multiple processes come into play and several different inter-logistics points are used where in-process materials are handled within the same factory or even within multiple semi-finished goods factories.

While each industry may have a slightly different process, we can narrow down the manufacturing process for insecticides into two broad steps – (a) technical grade pesticide manufacturing process and (b) formulation process for production and shipping of the final product.

In the active ingredient production process, various organic and inorganic raw materials are processed in reactors and passed through fractionation columns and the active technical grade pesticide made ready for shipping. There are some further steps including drying and packaging.

To improve the transportation, handling, and dispersion of the insecticide, the active ingredient has to be formulated into an end-use product. In the formulation process of the end-product, the active ingredient is powdered into the fine powder in a mill. The fine powder of the active ingredient is thoroughly mixed with a base solvent and other ingredients. The end-product may be dry or liquid and packed accordingly in boxes and bottles respectively.

In many of the steps requiring movement of raw material, grinding vessels blanketing etc. inert gas is required to prevent oxidation of many sensitive and volatile chemicals. In such cases, nitrogen is frequently used as the gas of choice. Nitrogen production on-site is easy and cost-effective, making it an ideal choice for inert mediums. Where ingredient or raw material pneumatic movement is required, Nitrogen is used as the carrier. During the preparation, inter-process storage tanks may be required for storing semi-finished goods. In the case of volatile chemicals or chemicals otherwise prone to spoilage due to oxygen contact, are kept in the nitrogen purged tanks and then nitrogen blanketing of these tanks is done on a continuous basis to avoid any further ingress of oxygen into the tank.

Another interesting use of nitrogen is in the packaging of the active ingredients or the end-product, where exposure to oxygen is harmful and not only spoils the end-product prematurely but also significantly reduces the shelf life of the product. An interesting phenomenon in case of insecticides is the collapsing of bottles in which air is left in the bottle’s headspace causing undesirable reactions inside and causing the bottle to develop a vacuum and thereby leading to deshaping the bottle. Hence, many manufacturers are choosing to purge the bottle with nitrogen to eliminate air from the bottle before filling of the insecticide and also to top off the headspace with nitrogen to avoid any air to remain in the bottle, before it is sealed.