Formulating a Career in Formulation Science

Date:05-03-2023

My journey into the world of Ag was highly atypical. During my final year of graduate school, I audited a class offered by one of my advisors called ″Formulation Engineering″. This was truly the first class taken during my higher education that excited me. I loved how formulation scientists used their knowledge of molecular interactions to create products with particular properties to meet the wants and needs of the consumer. It was a puzzle with infinite pieces. It was a scientific artform. It was what I wanted to do.

There is a steep learning curve entering the Ag sector as a fresh formulation scientist. I started my career in industry with a few relevant courses and no hands-on experience. I knew very little about agrochemicals, pesticides, or biopesticides, let alone how to develop them. After only eight months, I was asked by the VP of R&D to step into the role of Formulation Group Leader. It was a trial by fire, but through that trial I gained valuable knowledge on biopesticide formulation, field trials, regulatory, manufacturing, and the Ag industry as a whole.

Who is Certis Biologicals?

Certis Biologicals, located in Columbia, MD, is a pioneer in the development of pest management solutions and has become one of the world’s leading manufacturers and distributors of biopesticides. We own and operate three production facilities, two based in the United States for liquid and solid fermentation and one based in India dedicated to oil extraction for neem-based products. Certis Bio has the broadest portfolio of biological crop solutions for use in both organic and conventional agriculture on the market today: approximately 75 fungicides, insecticides, miticides, herbicides, and bacteriophages. We are now expanding into the realm of bio-stimulants and seed treatment formulations for row crops.

For most of its history, Certis Biologicals’ focus and strength has been manufacturing. Under the leadership of Amy O’Shea, that focus has widened to include research and development. We recently acquired the suite adjacent to our headquarters and have converted it into additional lab space, expanding our research workspace by 50%. The senior roles of formulation scientist, analytical chemist, and microbiologist have been filled, and once the new lab space is finalized, additional scientists will also be hired. In-house bioassay capabilities will be expanded to facilitate the development of experimental insecticides, nematicides, and fungicides. 

How does a formulation scientist develop a biopesticide?

When developing a biopesticide from scratch, a formulation scientist has to first decide which formulation type to pursue: a water dispersible granule (WG), a suspension concentrate (SC), an oil dispersion (OD), an emulsifiable concentrate (EC), etc. Croplife International’s ″Catalogue of pesticide formulation types and international coding system″ lists over 60 different types, so how does one choose? And what inert ingredients does one select? These are the main items I consider while making these decisions:

1. Properties of the active ingredient. The properties of the active ingredient determine which formulation types are available for product development. Bacteria grown via liquid fermentation at our Wasco, CA facility can be easily formulated into suspension concentrates. Fungi grown via solid fermentation at our Butte, MT manufacturing plant are hydrophobic, so oil dispersions or wettable powders are suitable formulation choices. Azadirachtin dissolves in oil, so emulsifiable concentrates are ideal for this product line. Forcing an active ingredient into an inappropriate formulation type can make for a costly and ineffective product.

2. Stability of the active ingredient. When live microbes are concerned, solid biopesticides tend to have longer shelf lives than liquid biopesticides. Farmers, however, prefer liquid formulations. If the liquid path is chosen for a formulation, inerts such as antimicrobials (contaminants can outcompete your active ingredient for resources), antioxidants, food sources, or agents that induce dormancy can be used to increase shelf life.

3. Loading of the active ingredient. How much active ingredient is desired? How much room does that leave for inert ingredients? There needs to be a balance. When formulating an extruded water dispersible granule (WG), inerts such as dispersing agents, disintegrating agents, wetting agents, extrusion aids, and stabilizers may need to be incorporated. If 90% active ingredient is desired for this WG, leaving only 10% for inert ingredients will likely result in a product with poor physical properties.

4. Function of the active ingredient. What biocidal activity does your active ingredient have: insecticidal, fungicidal, nematocidal, or herbicidal? An insecticide may need an inert that acts as bait to tempt insects to take a bite. A foliar fungicide can benefit from a sticker-spreader, and wetting agents can reduce leaching when a nematicide is applied in-furrow. Herbicides are most effective in low water hardness, so adding a water softener to the formulation can be beneficial. 

5. Regulatory. To be used in a (bio)pesticide, an inert ingredient must be approved for food use, and any formulation limits set in EPA 40 CFR part 180 must be followed. To be used in a (bio)pesticide approved for organic farming, the inert must be listed on either the EPA 4A or 4B lists or be declared OMRI-approved by the manufacturer. Because Certis Biologicals sells products globally, foreign regulations must also be consulted, such as Regulation (EC) No 1107/2009 (the European Union’s list of banned co-formulants).

 

What opportunities do you see at Certis Biologicals as a formulation scientist?

After conducting internal research on our product portfolio, I found several exciting opportunities to grow my skillset and to optimize formulations. Many of Certis Biologicals’ products are water dispersible granules (WGs) produced via pharmaceutical-grade batch equipment. My experience with formulating and manufacturing WGs had been limited to extrusion, so batch granulation was the first skill I learned. These granules have many positive attributes: organic formulations, low dust, excellent flow properties, and high suspension in water to name a few. One noticeable issue was the high manufacturing time and the low throughput per batch. 

Certis Biologicals’ manufacturing plant located in Wasco, CA produces over 15 granular products, which include manufacturing from seed fermentation through final packaging. In order to relieve batch-process manufacturing strain, we have invested in semi-continuous granulation equipment and technology. Not only will this new technology reduce granule manufacturing time, but it will also reduce energy consumption and overall manufacturing cost.

What advice do you have for aspiring formulation scientists?

Expertise as a formulation scientist is acquired through collective experience. Learn from every resource available to you, such as predecessors’ lab notebooks, peer-reviewed literature, and sectors other than Ag. Regulatory, Manufacturing, and Field Development will have views on product development that are not typically considered by a scientist, so listen and internalize. Finally, do not be afraid to fail. You cannot develop a successful biopesticide without taking chances, making mistakes, and getting messy (Ms. Frizzle, The Magic School Bus).

About the author

Dr. Brittany A. Nordmark is the Senior Formulation Scientist at Certis Biologicals. She attended Carnegie Mellon University for graduate school, earning her doctorate degree in Chemical Engineering and her master’s degree in Colloids, Polymers & Surfaces. After working briefly as a Formulation Scientist with a biopesticides company in California, she was promoted to Formulation Group Leader. Two and a half years later, she decided to return home to the East Coast. Dr. Nordmark has now been with Certis Biologicals for one year.