"Green Chemistry for Agro Chemicals Industry Sector"
Sustainability trends in Agrochemical Innovation and Research
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Syngenta Biosciences Pvt. Ltd. (SBPL): Our Purpose
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To be a Centre of Excellence in Organic and Analytical Chemistry and
contribute significantly to the innovation process in Syngenta Crop
Protection Research while adhering to highest standards of Health,
Safety and Environment
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Topics of Discussion:
● Introduction to Agrochemical Research and Agrochemicals
● Green Chemistry – Area of Focus
● SBPL journey of Sustainable R & D
- Lean Impact
- Reach Impact
- Technology Impact
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Pesticides
USE OF PESTICIDES – TYPES OF PRODUCTS
❖ Pesticides used in different settings: -
✓ AgriculturaL
✓ Veterinary
✓ Domestic
✓ Institutional
❖ Formulations: liquid, gel, paste, chalk, powder, granules, pellets, baits...
❖ Concentrations: from 2% to 80% of active ingredient
❖ Containers: glass, plastic or metal flasks, bottles, drums,
traps, plastic bags or paper bags....
Fungicides Rodenticides
Wood preservatives
Pesticides
PESTICIDES – CLASSIFICATION BY USE
Insecticides Herbicides
Fumigants
Insect repellents
Chemicals designed to kill, reduce or repel pests
Insects Weeds MouldsRats, mice,
moles
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Pesticides
PESTICIDES – RISKS AND BENEFITS
RISKS
❖Toxic to humans
❖Impact on environment
and ecosystems
BENEFITS
❖Crop protection
❖Food preservation
❖Material preservation
❖Disease control
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What to look for in a new lead compound
⚫ Does it have the right kind of activity?
➢ In vitro
➢ In vivo
➢ Spectrum (selectivity)
➢ Potency
⚫ Structure
➢ Novelty
➢ Amenable to modification
➢ No potential toxicity alerts (alkylating groups, Michael acceptors, etc)
⚫ Is the mode of action new?
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Pesticides
ORIGIN, TRANSPORT AND FATE
Distribution routes and "receptor" organisms for pesticides
used in agriculture
Air
Sediment
Target
Pest
Surface
water
Soil
Ground
water
-Crops
-Soil organisms
-Applicators
-Bystanders
-Wildlife
Humans
Wildlife
Plants
Cattle
Crops
Aquatic
organisms
Terrestrial
organism
Sediment
organism
1
1
2
3
5
4
6
7
1. Emission
2. Drift
3. Deposition
4. Sedimentation
5. Leaching
6. Drainage
7. Volatilization
A
.Laborde
Application
Spray
Granulate
Or
Seed
Treatment
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Need for Innovation and Development chemistry to be Sustainable
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Compound with given
physico-chemical propertiesPlant with his defence system
Nature, sun, humans
?
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The 17 sustainable development goals (SDGs) to transform our world: - 2030
GOAL 1: No Poverty
GOAL 2: Zero Hunger
GOAL 3: Good Health and Well-being
GOAL 4: Quality Education
GOAL 5: Gender Equality
GOAL 6: Clean Water and Sanitation
GOAL 7: Affordable and Clean Energy
GOAL 8: Decent Work and Economic Growth
GOAL 9: Industry, Innovation and Infrastructure
GOAL 10: Reduced Inequality
GOAL 11: Sustainable Cities and Communities
GOAL 12: Responsible Consumption and Production
GOAL 13: Climate Action
GOAL 14: Life Below Water
GOAL 15: Life on Land
GOAL 16: Peace and Justice Strong Institutions
GOAL 17: Partnerships to achieve the Goal
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What is Green Chemistry?
Innovation aimed at design, development, and implementation
chemical products, reactions, and processes that …
❑ minimize hazardous substances
❑ develop Processes are inherently safe
❑ reduce waste and environmental footprint,
❑ improve efficiency and economics
Noyori - “…green chemistry is not just a catchphrase. It is an
indispensable principle of chemical research that will sustain our civilized society in the twenty-first century and
further into the future.”R. Noyori, Synthesizing our future, Nature Chemistry, 2009,
1, 5-6.
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ThroughoutDevelopment
Green Chemistry Innovation to motivate internal and external waste & cost reduction
EarlyDevelopment
Establish the “ideal synthesis route” to enable maximum future process greenness with respect to co-produced waste
LateDevelopment
Optimize the “ideal synthesis route” with respect to Life Cycle Assessment
Drug Discovery
PreclinicalPhase1 Clinical
Phase2 Clinical
Phase3 Clinical
FDAReview
ManufactureOngoing Research
GreenSustainable Chemistry
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- Adding value sustainably
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Did you know?
We know of 7 000 plant species in the
world that are edible, but over 50% of
our plant-derived calories come
from only 3 species:
Corn Wheat Rice
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Did you know?
Due to drought and desertification each
year 12 million hectares of soil are lost
(23 hectares/minute!),
where 20 million tons
of grain could have
been grown
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Did you know?
Without fungicides, yields of most fruits and vegetables would fall by 50–90%, making fresh produce unaffordable
to many
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Who we are
One of the world’s leading agriculture
companies helping to safely feed the world
while taking care of the planet.
● Aiming to improve the sustainability, quality
and safety of agriculture with world class
science and innovative crop solutions
● Enabling millions of farmers around the
world to make better use of limited
agricultural resources through the use of our
technologies
● Committed to improving farm productivity,
rescuing land from degradation, enhancing
biodiversity and revitalizing rural
communities through partnerships,
collaboration and The Good Growth Plan
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90countries
104production and
supply sites
120research and
development sites
28,000employees
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Soybean
Cereals
Corn
Diverse field crops
Rice
Specialty crops
Sugar cane
Vegetables and flowers
Supporting key crops with Crop Protection and Seeds offers
78%
22%
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$13.5bn revenue in 2018
>50% emerging markets
Broad, innovative portfolio
Crop Protection, Seedcare, Pest
Control, Seeds, Biotechnology
Traits, Digital
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870 million people
go to bed hungry
We are committed to finding better ways to safely feed the world sustainably
Every day the
world’s population
increases by
200,000
By 2050, 5bn people
will live with water
scarcity – agriculture
uses 70% of fresh
water
Agriculture produces
30% of greenhouse
gases and 40% of
soil is degraded
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Adding value sustainably
As a business serving the agricultural industry, we help farmers safely feed a fast-growing world population. But there’s more: we aim to lead in sustainability.
The Good Growth Plan is not only driving the way we add value to a sustainable agriculture system; it’s measuring the results, so we can quantify the difference we make.
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Learn more at
www.goodgrowthplan.com
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More health
Less poverty
More biodiversity
Less degradation
More food
Less waste
One planet. Six commitments.
Make crops
more efficient
Increase average productivity
of the world’s major crops by
20% without using more land,
water or inputs
Rescue more
farmland
Improve the
fertility of 10
million hectares
of farmland on
the brink of
degradation
Look after every worker
Strive for fair
labor conditions
throughout our
entire supply
chain network
Empower smallholders
Reach 20 million
smallholders
and enable them
to increase
productivity
by 50%
Help biodiversity
flourish
Enhance
biodiversity on
5 million
hectares of
farmland
Help people stay safe
Train 20 million
farm workers on
labor safety,
especially in
developing
countries
The Good Growth Plan
We’ve made six commitments to help grow more food using fewer resources,
while protecting nature, and at the same time helping people in rural communities
live better lives
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In 2018, we measured
input efficiency changes
for 3,759 reference and
benchmark farms for 20
crops in 39 countries
Since 2014, we have
benefited 10.8 million
hectares of farmland
through soil conservation
practices
In 2018, we have covered 99.6% of our suppliers in our sustainability and fair labor programs
In 2018, we have
reached 19.5 million
smallholders through
training and sales
Since 2014, we have
benefited 6.4 million
hectares of farmland
through biodiversity
enhancing practices
Since 2014, we have
trained 33.8 million
people on safe use
The Good Growth Plan in 2018 – turning the commitments into tangible achievements
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Keeping our commitments relevant to society
Our six Good Growth Plan commitments help us quantify
how we contribute to the Sustainable Development Goals
set out in the United Nations Agenda 2030.
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SBPL Research Journey –Focus on Green and Sustainable chemistries
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2006-2010
2011-2016
2016-2019
5S
➢ Infrastructure Phase-1
➢ Global HSE Policy
➢ Basic Resource Planning
➢ Functional SOP’s
➢ Basic Financial and Resource Planning
➢ Infrastructure Phase-2
➢Sorting-Shining Phase of Lean Initiated
across functions on site including
➢Waster area,
➢ Stores
➢ Infrastructure
➢Engineering services
➢Laboratories
➢ Initiated metrics Based Monitoring Systems
➢Advanced Financial and Resource Planning
➢ Integrated SOP’s for Site
➢Standardisation-Sustain aspects of Lean
➢Auditing and Gap analysis for HSE and
Laboratories
➢Sustaining Good Practices on site across
functions
➢Advanced Financial and Resource Planning
➢Metrics based data collection, improvement
plan and implementation
➢ Implementation of Globally Recommended
Best Pracitces for Engineering Standards
SBPL Journey Towards Sustainability
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➢ INTIATIVES TAKEN
➢ SORTING OF PROCESSESS AND WAYS OF WORKING
➢ SORTING OF EQUIPMENTS FOR BETTER USE OF INFRASTRUCUTRE
➢ ACTIONS PLANNED WERE TO DISCARD/DONATE TO CLEAR THE WORK
AREA AND INCLUDES ITEMS SUCH AS
➢ EQUIPMENTS
➢ DOCUMENTS
➢ CHEMICALS
➢ GLASSWARE
SBPL Sustainability INITIATIVES:
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Period April-Aug-2013 Jan-14 March-14 June-14 Desired
Time Required (Minutes) 25 14 6 4 2
Lean (5S) Initiative to Reduce Time for Setting up of Reaction
June-2014 :
➢ Audit (by team of 2 members)
➢ Retrospective Data Collection
Key Changes:
➢ Rearranged lab storage (more space)
➢ Introduced new ways for storage
➢ Modified SOP for washing
➢ Combined order of better quality glassware
➢ Organized regular audit (Behaviors)
SBPL Sustainability INITIATIVES:
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➢ Equipments and materials not in regular use are stored in
designated areas
➢ Undesired Ways of Working were made Redundant
➢ Relevant Ways of Working were Refined
➢ Work areas were equipped with required items including
➢ EQUIPMENTS
➢ DOCUMENTS
➢ CHEMICALS
➢ GLASSWARE
Sustainability INITIATIVES AT SBPL
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➢ FOLLOWING BEST PRACTICES TO MAINTAIN THE FACILITIES
INCLUDING
➢ ENGINEERING MAINTENANCE POLICY AND STANDARDS
➢ SITE INTRASTUCURE MATURITY MODEL
➢ SCHEDULED AMC F
➢ SCHEDULED FACILITY MANAGEMENT INCLUDING HOUSEKEEPING
➢ STREAMLINED WAYS OF WORKING AND IMPLEMENTED
STREAMLINED PROCESSESS UNIFORMLY ON SITE
➢ APPROPRIATE RESOURCES ALLOCATED FOR THE INITIATIVES
SBPL Sustainability INITIATIVES:
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➢ RESOURCE PLANNING AND MANAGEMENT ACROSS FUNCTIONS
➢ SITE SOP’S AND DOCUEMENTATION
➢ MATERIAL MANAGEMENT ON SITE
➢ BENCH MARKED AGAINST GLOBAL GOOD PRACTICES IN THE
FORM OF POLICIES, CODE OF PRACTICES, STANDARDS ETC..
➢ VISUAL MANAGEMENT OF VARIOUS ACITIVIES ON SITE WERE
INSTALLED
SBPL Sustainability INITIATIVES:
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➢ Regular AUDITING, REPORTING AND RESOURCE ALLOCATION FOR
ACTIONABLE ITEMS
➢ REGULAR TOWN HALLS WITH EMPLOYEES FOR TRAINING AND
AWARENESS
➢ INITIATIVES TO REDUCE WASTE GENERATED FROM SITE
THROUGH VARIOUS PROGRAMS: REMOVE, REDUCE, RECYCLE
➢ METRICS BASED DATA MONITORING OF ALL ACTIVITIES ON SITE
FOR SUSTAINING EFFICIENCY
➢ PROCESSES TO SUSTAIN CHANGE MANAGEMENT
SBPL Sustainability INITIATIVES:
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Value Creation for Customers
➢ Quality, Quantity and Timely Delivery
➢ >95 % Success Rate in Project Deliverables
➢ Lean Initiatives in Sourcing – Financial saving
➢ Inventory Management - Reduction in ware house space
➢ WOW in lab has reduced failure in advanced stage – impact on reworking and waste generation
Value Creation for Site and Employees
➢ More organised work space
➢ Appreciation from local and statutory Bodies
➢ Empowering employees through various forums
➢ Scientific and technical
➢ Soft skill training
➢ Engagement events for site culture development
➢ More than doubled the productivity of scientist
➢ Improved HSE statistics
IMPACT OF 5S INITIATIVES IN SBPL
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Financial Budget No
of P
roje
cts
Value Creation at R&T
IMPACT OF 5S INITIATIVES IN SBPL
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Continued use of many polar aprotic solvents, and amides in particular, is likely to be restricted under
Reach, because of concerns about their reproductive toxicity. ‘NMP [N-methyl-2-pyrrolidone], DMF
[dimethylformamide] and DMAc [dimethylacetamide] have been workhorses of industry for a long time, but
their days are numbered, except maybe for some very specialist applications
The “REACH” ImpactRegistration, Evaluation, Authorisation and Restriction of Chemicals
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The health, safety and environmental spotlight is now
falling squarely on many of the solvents chemists take for
granted. A number of widely used ones are now facing
restrictions, if not outright bans, because of toxicity and
environmental concerns. What is being done to make
solvents safer and more sustainable?
Recycling and using new, greener solvents can make
chemical processes more sustainable
‘Industry has been chasing greener solvents for at least
20 years, but Reach [the EU regulations on registration,
evaluation, authorisation and restriction of chemicals] is
really forcing their hands,’ says James Clark, director of
the Green Chemistry Centre at the University of York, UK.
‘
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Initiatives Towards Sustainability: Solvent Selection
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Recommended
(or preferred)
to be tested first in a screening exercise, if
of course there is no chemical
incompatibility in the process conditions
Problematic
can be used in the lab or in the Kilolab, but
their implementation in the pilot plant or at
the production scale will require specific
measures, or significant energy
consumption
Hazardousstrong constraints on scale-up. Substitution
during process development is a priority
Highly
hazardous
Solvents to be avoided, even in the
laboratory
Four Classes of Solvent
What is a green solvent?
Physical and chemical
properties, toxicity,
environmental and safety
aspects and many more
parameters to be taken into
account…
Green Chem. 2007, 9, 927–934
Green Chem. 2016, 18, 288-296
Energy it takes to
produce 1kg of
solvent
Energy saved vs
(making new) by
recycling
Energy saved vs
(making new) by
incinerating
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Initiatives Towards Sustainability: Solvent Minimization
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Reduction of Solvent
➢ Process Driven: Validation, Consistency and Scale up
➢ Reuse: Solvents in a campaign
➢ Reduce: Process initiatives, alternate purifications
➢ Recycling: Recycle
Reduction of Solvent
➢ Reduced Risks, Enhanced Safety
➢ 75 % Reduction in Solvent Costs over 2 years
➢ 50 % in sourcing
➢ 25 % in waste management
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Initiatives Towards Sustainability: Solvent Selection
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➢ 2 % Reduction in Hazardous solvent
➢ 1.5 % Increase in Recommended solvent
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Chemical Process Development
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Batch and flow
● Classic way to do chemistry.
● Reagents are loaded into the reactor, mixed and
left to react.
● The products is collected at the end, after the
reaction has been completed and worked-up.
.
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DOI: 10.1021/acs.oprd.5b00325Org. Process Res. Dev. 2016, 20, 2−25
Reaction
Mixture
>5mm
Reagent A Reagent
B
Reagent A
Reaction
Mixture
~100µm
Reagent B
Key factors:
- Concentration
- Mixing
- Temperature
- Reaction time
Key factors:
- Residence time (flow rates)
- Mixing
- Pressure
- Temperature
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Advantages of implementing Flow solution at an early development stage
Introducing continuous flow at this point enables
• use of specific types of reactions that are very difficult to accommodate with the traditional batch
process.
• Applying continuous flow in early phase development also allows greater control over the reaction
• it also makes it possible to start building a process that can be commercially viable from the outset,
reducing the potential multiple iterations of a development cycle as the compound progresses from
phase to phase.
• The ability to optimise the process from the outset is a major advantage as it means that the best route
can be used, rather than one best suited to a batch operation.
• With continuous flow, all routes can be explored to find the most appropriate synthesis that can then be
progressed through all the different stapes of development.
• continuous flow offers a process that is scalable from the beginning, allowing the manufacture of a few
hundred grams or perhaps a kilogram of a compound, and this can be quickly increased to larger
quantities of material for a later phase, by increasing the scale of the equipment, or by extending the
processing time. This scale up can be done multiple times through to commercial quantities, as opposed
to batch manufacturing,
SCALE-UP (Pilot plant trials)-Transfer to Manufacturing/life
cycle management
Discovery Chemistry
Lead compound
Process Development – piloting
Flow chemistry
SCALE-UP (Pilot plant trials)-Transfer to Manufacturing/life
cycle management
Discovery Chemistry
Lead compound
Process Development – piloting
•-Optimization (change conditions and parameters)
•-Minor change of route / intermediate
•-Cheaper / more efficient reagents (new to market)
•-Environmentally-friendly reagents and effluent
•considerations
•-Yield / concentration improvement
•-Statistical methods
Chemical Process Development: 3-6 years
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WASTE MANAGEMENT FOR SUSTAINABILITY
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WASTE MANAGEMENT FOR SUSTAINABILITY
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Thank You!
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