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Advanced Agrochem
journal homepage: www.keaipublishing.com/en/journals/advanced-agrochem
A R T I C L E I N F O A B S T R A C T
Keywords: Pesticides might be the only group of poisonous chemicals that are widely sprayed into the environment, but the
Pesticides use of pesticides is inevitable for crop protection and infectious disease control. When an ideal new pesticide
Crystal engineering compound is selected, its properties must be optimized to realize the full potential of the compound and extend its
Polymorphs
lifespan in the market. Crystal engineering has proven to be a viable strategy for manipulating the properties of
Solid forms
solid-state pesticides. This review describes basic concepts of crystal engineering and its application in pesticide
development through representative cases reported mainly by large agrochemical companies. The solid forms that
present improved properties could justify patent protection, extending the market exclusivity of the pesticide
product. The purpose of this review is to present the potential impact of crystal engineering strategies on the
improvement of pesticide products, with emphasis on the importance of comprehensive characterization of the
crystallization behaviors of a selected pesticide during its entire life cycle.
https://doi.org/10.1016/j.aac.2022.09.001
Received 7 August 2022; Received in revised form 7 September 2022; Accepted 9 September 2022
Available online 15 September 2022
2773-2371/© 2022 The Authors. Publishing services by Elsevier B.V. on behalf of KeAi Communications Co. Ltd. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 1. Cost of agrochemical development (dashed line) versus screening success (solid line). Screening success ratio ¼ 1/number of compounds that need to be
screened for each product found. Reprinted with permission from Ref. 8. Copyright 2017 John Wiley & Sons.
The importance of crystal engineering has been well-known in the 2. Solid-state forms
pharmaceutical industry. Research on the solid-state forms of organic
materials has been flourishing during the last decades.12 In modern Organic compounds can exist in varieties of distinct solid forms, such
agrochemical chemistry, this topic not widely as widely represented in the as polymorphs, solvates (including hydrates), salts, cocrystals and
literature giving the consequences of solid-state considerations, in our amorphous solids (Fig. 2). Each form typically displays unique physical
view. A few solid-state considerations can be dated to the beginning of the and chemical properties that can profoundly influence the solubility,
green revolution (1950s).13 During the 1980s, agrochemical companies dissolution rate, bioavailability, hygroscopicity, melting point, stability
started to realize the problems associated with solid forms of the active and all other physical and chemical properties besides.11,15,16 In this
ingredients (AIs). For example, in 1986, S.I.P.C.A.M. (Societa Italiana section, we will provide the definition and background knowledge of all
Prodotti Chimici e per L'Agricoltura Milano S.P.A.) found that a new kinds of solid forms and briefly introduce the application of solid form
polymorph of chlorothalonil exhibited a reduced biological activity.14 research in the pharmaceutical industry.
By reviewing the representative cases on crystal engineering strate-
gies applied to solve the problems encountered during manufacture, 2.1. Polymorphs
formulation and application of pesticide products, this review aims to
highlight the important role of crystal engineering strategies in the A polymorph is a solid crystalline phase of a given compound
development of improved pesticide products, furthermore, increase the resulting from the possibility of at least two different arrangements of the
awareness of the solid-state chemistry of pesticides. To achieve this goal, molecules of that compound in the solid state.17 In other words, poly-
this review will start with a brief description on the background morphism describes crystalline substances in more than one form or
knowledge of the solid-state forms of organic materials, followed by a crystal structure can exist with distinct molecular conformations and
detailed illustration on the application of crystal engineering in pesticide intermolecular interactions.18
development. The first description of polymorphism in an organic molecular crystal
40
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
was reported 190 years ago.19 In 1832, W€ ohler and von Liebig found that 2.3. Solvates (pseudopolymorphs)
the needle-like crystal of benzamide transformed into a rhombohedra.
The crystal structures of these two habits were determined to be different The most common method for polymorph screening is solution
only in 2005 with the help of the third-generation synchrotron sources.20 crystallization, which involves the presence of at least two kinds of
Fifteen years later, the structure of needle-like Form II was further refined molecules, the organic compound and solvent. If the solvent molecules
using a new set of high-resolution synchrotron data and crystal structure are incorporated into the host crystal lattice in the process of crystalli-
prediction methods.21 The difference between crystal structures of a zation, the formed crystal is called a solvate, and if the solvent is water, it
polymorphic molecular compound, resorcinol, was first established by is called a hydrate. The solvates can be formed under many circum-
Robertson in 1935, in the early days of crystallography.22 stances involving the presence of a solvent, such as crystallization, slur-
Polymorphism was thought to be exceptional at first, but as single ring, wet granulation, storage, and so on.
crystal structure determination became faster, it was recognized that it is A solvate displays unique unit cell parameters and molecular packing,
the norm for organic molecules. Over 80% of the pharmaceutical mole- and this phenomenon is analogous to polymorphism in that the AI can
cules can crystallize in multiple crystalline lattices.23 It has been claimed occupy a new crystalline state. To distinguish solvates from polymorphs,
that “every compound has different polymorphic forms, and that, in general, the solvates were sometimes called as “pseudopolymorph” in books or
the number of forms known for a given compound is proportional to the time literature,30 though this term is misleading.31 Polymorphs have the same
and money spent in research on that compound".17,24 For example, imida- composition but different geometries. Thus, it is a misnomer to then
cloprid, one of the world's leading insecticides, was long thought to have collect crystals with different compositions under the banner of poly-
only two polymorphs, forms I and II. Recently, seven new polymorphs of morphism no matter how qualified, and pseudo is not a very clarifying
this insecticide were found, making the number of forms known for prefix. This term should be avoided.
imidacloprid rise from two to nine.25 A solvate is the simplest form of an inclusion compound. Solvates can
be classified into two categories based on the incorporation mode of
2.2. Amorphous solid state solvent molecules in the crystal lattice.32 In Type 1 solvates (Fig. 3a), the
solvent molecules occupy isolated sites; Type 2 solvates (Fig. 3b) collect
In a mono-component system, the organic molecules do not really solvent molecules in channels and are often called channel solvates.
have to pack in a long-range highly ordered periodic arrangement, which Type I solvent molecules form hydrogen bonds and van der Waals
means the solid is not necessarily crystalline. If the solids consist of interactions only with host molecules and make an essential component
molecules with no periodic arrangement at the microscopical level, and of the crystal structure, thus the host compound and solvent are generally
do not possess a distinguishable crystal lattice, it is called an amorphous in a stoichiometric ratio. During the desolvation process, the solvent
solid.26 Though “amorphous solid” might be used synonymously with molecules escape, and the original crystal structure will collapse,
“glassy solid”, nowadays, “glassy solid” is considered to be a particular resulting in phase transformation to an amorphous state or a solvent-free
case of “amorphous solid”: glassy solid commonly refers to an amorphous crystalline form.
solid below its glass transition temperature.27 In contrast to a crystalline For channel solvates, the solvent molecules form connections with
solid, an amorphous solid does not have a melting point, instead, it has a adjacent solvent molecules, resulting in “channels” along a crystallo-
more extended softening process. In other words, amorphous solids melt graphic axis. In such systems, the interactions between solvent molecules
over a range of temperature. and host molecules are relatively weak. During the solvation process, the
Compared to polymorphism, amorphism is an even more frequent crystal lattice may undergo expansion in a crystallographic direction and
phenomenon. Any given crystalline solid can be made amorphous, as result in changes in unit cell dimensions, which can be observed as shifts
long as the cooling/quenching is rapid enough. For example, while all ice in diffraction peaks of powder X-ray diffraction (PXRD) pattern. During
on earth is crystalline, water can also form amorphous ice by cooling to the desolvation process, whether the crystal lattice will collapse depends
its glass transition temperature (137 C) in milliseconds.28 on the extent of the mechanical effects of removing solvent molecules
The same compound may display more than one distinct amorphous from the depths of the lattice structure.32 Most of the channel solvates
phase.29 This phenomenon has been called amorphous polymorphism, in can sorb and liberate solvent molecules in a continuous manner, resulting
analogy with crystalline polymorphism, or more succinctly, in continuous changes in the stoichiometry of solvent to host compound
polyamorphism. and changes in crystal lattice parameters according to solvent content in
the environment.
41
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
2.4. Salts and cocrystals tool for manipulating the desired physicochemical properties during
drug development.
The definition of salts is widely known by the chemistry community The dramatic change in physicochemical properties resulting from
as a substance produced by the reaction of an acid with a base. In the various crystal forms not only impacts patients and the pharmaceu-
contrast, the concept of cocrystals is relatively less well-publicized. tical manufacturer, but also influences the US Food and Drug Adminis-
Cocrystals are solids that are crystalline single-phase materials tration (FDA). Several regulatory documents addressing crystal forms
composed of two or more different molecular and/or ionic compounds and changes in solid forms have been released by FDA in the last 20 years,
generally in a stoichiometric ratio which are neither solvates nor simple as shown in Table 1.
salts.33,34 The first molecular cocrystal was reported as early as 1844, For the pharmaceutical manufacturer, one other significant benefit of
when W€ ohler mixed solutions of quinone (yellow) and hydroquinone conducting solid form studies is that solid-state forms are patentable. The
(colorless) and produced a green crystalline substance.35 The crystal patents on crystal forms may provide an extra duration of protection for
structure of the green substance was solved in 1958, and showed alter- the marketed products and thus bring additional commercial benefits.
nate quinone and hydroquinone molecules connected by hydrogen bonds The crystal engineering of organic compounds has also been flourishing,
in the unit cell.36 more than 2000 literature have been published each year globally since
Apparently, cocrystals, salts and solvates are all multicomponent 1996, and the number is still rising (Fig. 4).
molecular crystals.37,38 Cocrystals/Salts differ from solvates and hydrates
in that the components are all solids when they exist as single-component 3. Application of crystal engineering in pesticide development
forms. Cocrystals can be distinguished from salts if the intermolecular
interactions in the cocrystal lattice are nonionic; the molecules of Compared to the popularity of crystal engineering in the pharma-
different components are held together by interactions, such as hydrogen ceutical industry, the solid-state chemistry study of pesticides has not
bonds, π-π stacking, van der Waals interactions and halogen bonds. gained comparable attention in the agrochemical industry. According to
The distinction of cocrystals and salts is whether the proton transfer incomplete statistics by authors, there are only around two hundred
occurs between AIs and co-formers. Proton transfer is complete in a salt, publications, including patents and peer-reviewed literature, on agro-
while absent in a cocrystal. Otherwise, a continuum state exists between chemical solid forms, far fewer than for active pharmaceutical in-
the salt and cocrystal, in which the proton can be equipoised. The dy- gredients (APIs). Since the variation of solid forms can result in
namic position of proton in the multicomponent crystals can be deter- prominent properties modification of the compound, regardless of its
mined with a variety of techniques, such as X-ray diffraction, X-ray application, it is reasonable to believe that the crystal engineering
photoelectron spectroscopy (XPS), solid-state NMR spectroscopy and IR strategy can contribute to the development of better pesticide products.
spectra.34,39,40 The acidity (ΔpKa) rule is commonly applied for pre- Indeed, there are excellent cases where crystal engineering technologies
dicting whether the two molecules can form salt or cocrystal. When the have been applied to solve the problems encountered during the devel-
ΔpKa value between an acidic/basic AIs and basic/acidic co-former is opment of pesticide products. In this section, representative cases will be
greater than 3, a salt generally forms. When the ΔpKa < 0, a cocrystal reviewed to show the application of crystal engineering in pesticide
formation is predominant. However, when the ΔpKa between 0 and 3, the development.
extent of proton transfer in the solid state is difficult to predict, and a
continuum state exists.41 3.1. Bioactivity
2.5. Crystal engineering in the pharmaceutical industry Since the discovery of synthetic pesticides, bioactivity has been the
most important property of a pesticide. The bioactivity of a compound
Different solid forms of APIs (active pharmaceutical ingredients) against pests makes the compound a potential pesticide. Though crystal
normally possess different physicochemical properties, such as solubility, engineering of pesticides has never been a sharp focus in solid-state
dissolution rate, melting point, stability, especially, the bioavailability of chemistry and pesticide science communities, just 8 years after the dis-
APIs, as shown in the famous case of ritonavir.42 covery of DDT's insecticidal action, it was found that the plate-shaped
Ritonavir was marketed in 1996 as capsules of Form I by Abbott (now DDT crystals were more toxic than the needle-shaped crystals.13 This
AbbVie). However, Form I of ritonavir transformed to a less soluble Form first case indicated a correlation between the crystal state and the
II in capsules, leading to a significantly lower bioavailability and more bioactivity of pesticides.
than $250 million USD lost.43 Since then, a thorough polymorphic It is becoming acutely well-known in the pharmaceutical industry
investigation of APIs has been a must-do in the development pipeline of that different solid forms of APIs possess distinct bioactivity and
pharmaceutical products. Recently, a third polymorph of ritonavir was bioavailability in 1998, when the ritonavir capsule supplies failed due to
discovered via melt crystallization by AbbVie researchers.44 the sudden appearance of a new much less bioactive polymorph. The
Other than polymorph, other solid-state forms have their character- crystallographic-dependent bioactivity of pesticides, however, has not
istics. Amorphous solids are normally less thermodynamically stable than been systematically studied until the 2010s.59 Nevertheless, this does not
their crystalline forms, they usually have higher solubility, faster disso- mean that pesticides are less likely to have polymorphs, or the bioactivity
lution and improved bioavailability.45–47 Traditionally, salts have been a difference between pesticide polymorphs is trivial. As stated, the
topic option for improving the pharmacokinetic properties of a phar-
maceutical molecule.48,49 Now cocrystals have emerged as a strategy for
Table 1
systematically properties manipulation by selection of an appropriate
Several regulatory documents addressing crystal forms and changes in solid
co-former molecule.50,51 Though solvates containing organic solvent forms released by FDA in the last 20 years.
molecules are always not preferred for further formulation development,
Year Regulatory documents
the screening of solvates is still necessary to prevent the formation of
undesired solvent crystals.52,53 2000 Q6A Specifications: Test Procedures and Acceptance Criteria for New
Substances and New Drug Products: Chemical Substances 54
As one can learn from above, the unique advantage of the crystal
2007 ANDAs: Pharmaceutical Solid Polymorphism: Chemistry, Manufacturing, and
engineering approach is that the chemical structure of the compound can Controls Information55
remain unchanged, while the physicochemical properties of this com- 2013 Guidance for Industry on Regulatory Classification of Pharmaceutical Co-
pound, including bioavailability, can be manipulated according to the Crystals 56
requirement of the manufacture, formulation, and application process. 2018 Regulatory Classification of Pharmaceutical Co-Crystals: Guidance for
Industry 57
Because of this advantage, crystal engineering has become an important
42
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 4. Number of publications reported with the solid forms including the keyword polymorph, amorphous, cocrystal/co-crystal, solvate/hydrate in title during the
period 1960–2021 in the Scopus database.58
inevitable polymorphism of organic compounds resulted in a reduced commercially available Form I during the crystallization process, tech-
biological activity of chlorothalonil, one of the most used fungicides in nologies to produce pure Form I, which possesses higher activity, have
the world.14 been extensively pursued by manufacturers.61–64
Fig. 5. (a) Molecule structure of chlorothalonil, (b) crystal structure of Form I and (c) crystal structure of Form II.
43
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 6. (a) Molecule structure of DDT, (b) polarizing microscope photograph of two forms, (c) crystal structure of Form I and (d) crystal structure of Form II. Adapted
with permission from Ref. 59. Copyright 2017 Wiley-VCH.
DDT might be dependent on its crystal structure. Further bioassays polymorphs of lindane were well characterized. Bioassay for three
indicated that the Form II of DDT was more active than Form I against polymorphs of lindane against Drosophila melanogaster revealed an in-
Drosophila melanogaster.59 verse correlation between lethality and thermodynamic stability of
The DDT work further emphasized the importance of the solid-state polymorphs.66 This correlation was later verified by the difluoro
structure of crystals, especially crystals of contact insecticides, which congener of DDT, DFDT. The amorphous form of DFDT, solid form which
the insects directly encounter. In the following work, two new possessed the highest free energy, was more active than the two
Fig. 7. (A) Molecular structure of DM. (B) Microcrystals in suspension concentrate (Suspend SC, DM concentration: 5%), a formulation used for indoor residual
spraying (IRS). (C and D) Melt grown DM (C) Form I and (D) Form II spherulites observed between crossed polarizers. PXRD confirmed that the fibers in the spherulite
were oriented along the crystallographic <010> direction. (E) PXRD data for Form I (blue) and Form II (orange) from their respective films. (F and G) Single crystal
structures of forms (F) I and (G) II determined at 100 K. Reprinted with permission from Ref.70. Copyright 2020. Published under the PNAS license.
44
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
crystalline forms towards Anopheles quadrimaculatus.67 larger particles during the field application of the product. Therefore,
Deltamethrin: Deltamethrin (DM), first developed in 1973, was the aggregation and particle enlargement of technical materials or AIs in
most active synthetic insecticide at the time.68 As one of the most formulation should be avoided or eliminated. Considering that low
commonly used pyrethroids with high selectivity, it has been reputed as melting points, inappropriate solid forms and undesired phase trans-
Michael Eillott's billion-dollar crystal and “crowning achievement”.69 By formation are common mechanisms behind the aggregation and particle
melt crystallization, a new polymorph of deltamethrin, Form II (Fig. 7), enlargement phenomenon, crystal engineering tools have been applied
was developed and found to be twelve times faster acting than the accordingly to tackle the challenges.
commercially available Form I against Anopheles quadrimaculatus
mosquitoes (Fig. 8).70 The simple preparation method and markedly 3.2.1. Technical materials with a low melting point
greater efficacy of Form II provided an affordable tool for infectious Melting point is an essential consideration for pesticide development.
diseases and crop protection. A researcher from International Vector For processing, formulation and storage purposes, the AI should be a
Control Consortium (IVCC), an organization that specializes in producing material having a high melting point. However, a large amount of such
tools for vector-borne disease control, commented that “this is another organic compounds are amorphous or have a melting point lower than
great example demonstrating how critical the physical structure of an active 60 C (Table 2).
ingredient is in the interaction with insects”.71 Low melting AI solids are prone to melt when the pesticide is pro-
Imidacloprid: Imidacloprid (IMI) is an insecticide belonging to a duced, dried, transported, stored, or used.15,80,81 Also, it will accompany
class of chemicals called the neonicotinoids, which act on the central material thickening, which leads the pesticides to grind difficultly, clog
nervous system of insects. As the world's leading insecticide, the poly- the filter equipment, adhere to the container walls, or even block spray
morphism of imidacloprid has been extensively studied and it has long nozzles. Moreover, due to substantial temperature fluctuations that may
been thought to have two polymorphs.72–75 By both solution crystalli- occur during the processing and storage of pesticide formulations, the
zation and melt crystallization, seven new imidacloprid polymorphs were solid particles of AI may go through cycles of melting and recrystalliza-
developed in 2021.25 The thermodynamic stability of all nine poly- tion, leading to the generation of large and undesirable particles, which
morphs was evaluated from melting points and phase transformations may block spray nozzles during the application of the product.
(Fig. 9). The bioactivity of three newly developed polymorphs and Form I Fortunately, the melting point can typically be tuned by crystal en-
were correlated with their free energy ranking. It was found that Form IX gineering. Pyraclostrobin, developed by BASF SE (Badische Anilin-und-
was almost nine times faster acting than the commercial Form I against Soda-Fabrik Societas Europaea) is the best-known example.
Aedes, Anopheles, and Culex mosquitoes as well as Drosophila. Notably, the Pyraclostrobin: Pyraclostrobin, as a quinone outside inhibitor (QoI)
highly active Form IX was stable against transformation for at least six fungicide discovered in 1993, quickly became the second-largest fungi-
months, making it a potential tool for practical use in the field. cide in the world by sales.82 This broad-spectrum fungicide has protec-
tive, curative, eradicative and systemic properties. The most glaring
3.2. Aggregation and particle enlargement disadvantage of pyraclostrobin is its low melting point.
Before 2006, the commercially available pyraclostrobin was amor-
One of the most obvious differences between pesticides and drugs is phous, its glass transition temperature was lower than 55 C.83 When
the delivery methods. While most solid pharmaceutical formulations are suspensions or granules were prepared, the pesticide technical material
oral doses, most solid pesticide formulations are designed for foliar will melt, aggregate, and then block the grinding equipment.84 To solve
treatment, such as wettable powders, water-dispersible granules, sus- this problem, BASF SE discovered four new polymorphs of pyraclos-
pension, and so on. In other words, for crystalline pesticides, the mi- trobin, dubbed Form I to IV.85 Form IV had the highest melting point at
crocrystals of AIs should be small enough, so that the particle can pass the 62–72 C. The new polymorph could be formulated as a suspension
spray nozzles, or can be made as a stable suspension formulation. concentrate. Form V of pyraclostrobin was prepared in 2016, further
However, possible aggregation and particle enlargement of solid increasing the melting point (Fig. 10).86 Polymorphs of pyraclostrobin
microparticles in suspension make it difficult to maintain the product as a with a higher melting point had better physical properties, avoiding the
homogeneous formulation. Besides, the spray nozzle may be blocked by melting and aggregation during mechanically grinding, thus overcoming
45
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 9. Imidacloprid polymorphism. Reprinted with permission from Ref. 25. Copyright 2021 American Chemical Society.
the difficulties in formulation development. Polymorph manipulation large particles and clogging spray nozzles. In 2008, Syngenta Ltd.
can improve melting points, but normally, in a relatively small range. designed cocrystals of propiconazole with high melting co-formers, such
Development of cocrystals of AIs provides another option for melting
point adjustment in a larger range. For example, if a higher melting
cocrystal is desired, then a higher melting co-former should be selected
and vice versa.
BASF SE designed two cocrystals of pyraclostrobin (PYR) with 4-
hydroxybenzoic acid (4HBA, melting point of 213 C 87) and
thiophanate-methyl (TM, melting point of 175 C 88), respectively
(Fig. 11).89,90 The melting point of cocrystal of pyraclostrobin with 4HBA
was increased to 114 C, and the melting point of PYR-TM cocrystal
increased to 150 C. As shown in Fig. 10, the cocrystals with high melting
co-former possessed much higher melting points than the pure crystalline
pyraclostrobin.
Propiconazole: Propiconazole has a low melting point and melts
quickly during production and storage. This pesticide might recrystallize
from the melt when the environment temperature drops again, producing
Table 2
Melting point data of some pesticides.
Pesticides Melting point ( C)
Pyraclostrobin 55-72 76
Flusilazole 5377
Pendimethalin 55-57 78
Lambda-cyhalothrin 49.2 79
Fig. 10. The melting point of different solid forms of pyraclostrobin.
46
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
as 4,40 -dihydroxybiphenyl (Fig. 12, melting point of 283 C). The coc- 3.2.2. Phase transformation
rystal had a higher melting point (around 130 C) than the commercially In addition to a low melting point, phase transformation is another
available versions of propiconazole.91 common reason for aggregation and particle enlargement. As mentioned
This new solid state of propiconazole had a melting point above the above, different crystal forms of pesticides have different thermodynamic
temperature range normally associated with processing and storage, thus stabilities, which may lead to a phase transformation. For most solution
it will not undergo aggregation and particle enlargement events during crystallizations, solvents mediate phase transformation happens. The
its formulation and storage. In addition, the cocrystal with a higher metastable solid forms tend to transform to a more stable solid form,
melting point could also now be manufactured as suspension where molecules detach from the metastable solid forms and then attach
concentrates. to a more stable solid form, resulting growth of the stable solid form.
Flupyradifurone: Flupyradifurone has a low melting point, about Solid-in-liquid dispersions, for example, suspensions, are stable only
72 C. It is easy to melt and adheres to the wall of the container during within a narrow range of particle size. Thus, the elimination of crystal
storage and transportation. In 2010, Bayer designed and synthesized two growth which accompanies the phase transformation is significant for
cocrystals of flupyradifurone with salicylic acid and oxalic acid, respec- development of a stable formulation suitable for agricultural use.95,96
tively (Fig. 13).92,93 The melting point of the flupyradifurone-oxalic acid Pendimethalin: Pendimethalin is a broad-spectrum herbicide for
cocrystal was about 122 C, much higher than that of the pure flupyr- pre-emergence and early post-emergence control of weeds. In the solid
adifurone. The elevated melting point allowed flupyradifurone to be state, this herbicide exhibits two polymorphs, one orange-colored, the
treated at elevated temperatures. Similar work with flusilazole and imi- thermodynamically stable form, Form I, and the bright-yellow meta-
dacloprid could be found in the literature.77,94 stable form, Form II (Fig. 14). The yellow Form II slowly converts to the
more stable orange Form I, which can take months or years to complete.
The slow transformation leads to crystal growth of stable Form I,
resulting in a significant problem in manufacturing stable suspension of
the herbicide for commercial use.97
For systems like pendimethalin, it is important to control the poly-
morphic purity of technical material, so that the most stable form is
selected and manufactured for formulation preparation.
Prothioconazole: Prothioconazole is a triazolthione fungicide
developed by Bayer, which quickly gained popularity due to its broad
spectrum of activity. The thermodynamically metastable Form I of pro-
thioconazole leads to unwanted crystal growth during preparation or
storage. In 2003, Bayer developed a thermodynamically stable new
polymorph of prothioconazole, Form II, preventing the occurrence of
Fig. 12. Molecular structures of propiconazole and 4,40 -dihydroxybiphenyl.
crystal transformation, causing no problems in preparation or storage,
neat or in the form of suspension concentrates.98 Both polymorphs of
prothioconazole were systematically investigated by polarized optical
microscopy and X-ray diffraction (Fig. 15).11
Polymorphs can be monotropic or enantiotropic.99 Monotropic
polymorphs, such as pendimethalin and prothioconazole mentioned
above, retain their relative thermodynamic stabilities at all temperatures
before melting. For such systems, using the thermodynamically stable
polymorph as neat material or in the formulation will cause no problems.
The thermodynamically stable polymorph in monotropic systems are not
subject to unexpected or troublesome transformation. In the case of
Fig. 13. Molecular structures of flupyradifurone, salicylic acid and oxalic acid.
Fig. 14. (a) Molecular structure of pendimethalin, (b) crystal structure of Form I (orange) and (c) crystal structure of Form II (yellow).
47
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 16. (a) Molecular structure of metazachlor, crystal structures of (b) orthorhombic Form I, (c) triclinic Form II and (d) monoclinic Form III of metazachlor.
48
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
49
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 18. Schematic representation of the formation of bixafen butyrolactone solvate. Adapted with permission from Ref. 11. Copyright 2022 John Wiley & Sons.
tramat, and solved by the development of a new polymorph Prothioconazole Form 15 20 115
(Fig. 19).110,111 II
116
Atrazine 33 22
117
Simazine 5 20
118, 119
Azoxystrobin 6.7 20
3.3. Water solubility Chlorantraniliprole 1 20 120
121
Fipronil 1.9 20
122, 123
Water is everywhere during the lifecycle of pesticides, including Dufulin 40 22
124
formulation preparation, plant uptake, rainfall, leaching, environmental Thiram 16.5 20
125, 126,
Tebuconazole 36 25
decomposition, and so on. Therefore, during the period, the bioavailability 127
and environmental toxicity of pesticides are all impacted by water Boscalid 4.6 20 128
solubility.
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X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 20. (a) Molecular structure of ametryn, crystal structures of (b) ametryn-fumaric acid salt, (c) Form I and (d) Form II of ametryn-maleic acid salt.
51
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
toolbox, including salts, cocrystals, amorphous solid, polymorphs and insecticide worldwide.145
solvates, provides a possibility to achieve such a goal. Following, we will However, the high solubility of neonicotinoids (Fig. 23, Table 6) led
exhibit how crystal engineering toolbox helps to overcome the shortages to excessive exposure to air, soil,146 water, or living organisms, which
of highly soluble pesticides. poses a massive threat to the environment147 and biological safety.148
Therefore, maintaining effects over a long period and reducing the
3.3.2. Highly soluble pesticides phytotoxicity and pesticide pollution by controlling the release of
Lots of pesticides are regarded as highly soluble pesticides, especially neonicotinoid pesticides have been considered.149,150
when their water solubilities are greater than 1000 ppm. Highly soluble Acetamiprid: Acetamiprid, an odorless neonicotinoid insecticide
pesticides will travel with water through the soil as it moves in the marketed by Nippon Soda, is highly soluble in water (4200 ppm at
environment, which may increase their probability of reaching 25 C). In 2006, Nippon Soda developed four cocrystals of acetamiprid,
groundwater. which showed a good capability of control release, the solubility of
Besides, the high-dissolving pesticides will quickly leach out before acetamiprid was reduced by about 10 times (Fig. 24).159
acting on the target,136 resulting in a short effective duration.113,137 To In 2014, a series of novel cocrystals consisting of a diamide insecticide
achieve a long-lasting pest control effect, pesticides are often applied at a and a neonicotinoid, such as acetamiprid, imidacloprid, thiamethoxam,
high frequency, causing unnecessary economic costs and further envi- clothianidin, thiacloprid, dinotefuran, were further developed to modify
ronmental pollution.138,139 the water solubility of neonicotinoids.160 The newly developed cocrystal
To solve these problems, controlled release of highly soluble pesti- of neonicotinoids showed much lower water solubility than the corre-
cides has been a widely studied field in formulation development.137 sponding neonicotinoid itself. Thus, the cocrystals enabled a release of
Various materials, such as alginate,140 biodegradable polymers, neonicotinoids into the water at an adequate rate, and thereby excellent
gel-based nanocomposites,141 and porous calcium carbonate micro- insecticidal effects were maintained over a long period without causing
spheres142 have been applied as the carrier for the development of a phytotoxicity on useful plants.
slow-release formulation of highly soluble pesticides. Metalaxyl: Metalaxyl is a systemic fungicide with high water
While scale-up of herbicide encapsulation technologies is developing,
the crystal engineering toolbox, which has been proved to be a solid
strategy to manipulate the release profile of bioactive compounds in the
pharmaceutical industry, offers a different way to tackle the challenge. As
one can imagine, the formation of salt is less likely to be able to reduce
water solubility, thus, co-crystallization has been the most frequent
option.
Neonicotinoids are a class of neuro-active insecticides developed
based on the chemical structure of nicotine. High insecticidal potency
and low mammalian toxicity143,144 ensured the popularity of neon-
icotinoids, which occupy a 24% market share as the most widely used
Table 6
The water solubility of highly soluble neonicotinoids.
Pesticides Water solubility (g/L) Temperature ( C)
151
Acetamiprid 4.2 25
Imidacloprid 0.61 152 20
Thiamethoxam 4.1153 20
Clothianidin 0.327 154 20
Thiacloprid 0.185 155 20
Dinotefuran 40 156 20
Nitenpyram 590 157 20
Fig. 24. Dissolution-time profiles of acetamiprid and its cocrystals in water
Flupyradifurone 3.2 158 20
at 25 C.159
52
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
3.4. Stability
3.4.1. Hydrolyzation
Both pinoxaden and mesosulfuron have a problem of stability
(Fig. 26). Their formulations often result in the rapid degradation of the
compound due to hydrolyzation, which has a negative impact on the
quality of the product and limits its useful shelf life. To solve this prob-
lem, the cocrystals of pinoxaden with an antioxidant, such as butylated
hydroxyanisole (BHA), butylated hydroxytoluene (BHT) or tert-butyhy-
droquinone (TBHQ), were developed by Adama Agan Ltd. to improve the
chemical stability.164 The formulation of cocrystal had a stabilizing effect
Fig. 26. Molecular structures of pinoxaden and mesosulfuron. on pinoxaden, delaying its chemical degradation (Table 7).
Amitraz: Amitraz is practically insoluble in water and relatively
Table 7 stable to temperature and light under anhydrous conditions. However,
Stability test of the cocrystal of pinoxaden with antioxidant BHA and compared when it encounters water, it is prone to hydrolysis. If the product is stored
with the reference formulation.164 in humid regions for a long period, it deteriorates rapidly.165 However,
Concentrations of pinoxaden in Formulation of Formulation of three crystalline forms (forms A-C) and an amorphous form of amitraz
the formulation (w/w%) Pinoxaden Pinoxaden-BHA cocrystal (Fig. 27a) showed completely different hydrolysis rates.166 As shown in
Starting 6.12 Fig. 27b, the decomposition rate of the amorphous form decreased more
2 weeks at 54 C 5.58 6.07 rapidly with time compared to the other forms, while Form C exhibited a
(-8.82%)a (-0.82%)
relatively slow decomposition rate. Thus, the suspension stability of
3 weeks at 54 C 5.55 6.00
(-9.31%) (-1.96%)
amitraz can be improved by replacing polymorphs, which provided an
a
additional possibility for formulation development.
The number in brackets reflects for each concentration of the herbicide Propionyl brassinolide: Propionyl brassinolide is a plant growth
pinoxaden was reduced, with respect to the initial concentration.
regulator discovered from rape pollen in 1979.167 It is effective on lots of
crops but cannot be stored for a long time in a humid environment due to
hydrolyzation. The commercially available propionyl brassinolide was
solubility (8.4 g/L at 22 C). The compound is poorly adsorbed by the soil usually manufactured as an amorphous solid, extremely susceptible to
particles, thus susceptible to mobility or runoff from treated areas, and hydrolysis. Once the material was stored under a humid and hot envi-
negatively impacting the environment. By selecting a water-insoluble ronment or dispersed in water, hydrolysis occurred. Therefore, a higher
pesticide, prothioconazole, as a co-former, Bayer developed a cocrystal amount of the product had to be applied to ensure the growth regulation
consisting of metalaxyl in 2013 (Fig. 25), reducing the water solubility of effect.
metalaxyl by 30 times, and achieved the goals of controlling release.161 A crystalline form of propionyl brassinolide was prepared by Rotam
Agrochem.163 After one week of storage as a suspension at 54 C, the new
Fig. 27. (a) SEM photomicrographs of the amitraz four solid forms. (b) Amount vs time hydrolysis plots for amitraz suspensions in aqueous phosphate buffer (pH 5.8)
at 30 C. Reprinted with permission from Ref. 166. Copyright 2004 American Chemical Society.
53
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 28. Schematic representation of the cocrystal synthesized from the combination of pyrimethanil and co-former dithianon.
crystal form sample was only hydrolyzed by less than 3%, while the remedy.
amorphous sample was hydrolyzed by 50%. With the significantly In 2004, synthesis salts of pyrimethanil were found to slow down
improved chemical stability, the newly developed crystalline form of sublimation.168 In 2008, the famous cocrystal of pyrimethanil and
propionyl brassinolide was stable after prolonged storage, thus suitable dithianone was developed by BASF SE,169 with detailed crystal structure
for the preparation of commercial formulations such as suspension con- information provided in 2016 (Fig. 28).170
centrates or oil-based suspension. Just one year later, this cocrystal was successfully launched to the
market as the main component of fungicide product Vision Plus, making
3.4.2. Sublimation the cocrystal of pyrimethanil and dithianone the only commercialized
Pyrimethanil: Pyrimethanil has a high vapor pressure, is accessible pesticide cocrystal product until 2022.
to sublimation under high-temperature conditions, thus has a short The cocrystal in Vision Plus had several advantages over the formu-
effective duration. To overcome this shortage, development of multi- lation without cocrystal. In addition to the complementary fungicidal
component solid forms of pyrimethanil has been regarded as leading effect providing by two AIs, the effect and duration of pyrimethanil-
Fig. 29. Schematic representation of the cocrystals synthesized from the combination of three constituents of essential oils and two co-formers. Thumbnail images of
the corresponding crystalline structures showing the core EO-co-former assemblies. Blue dotted lines represent the EO/co-former intermolecular H-bonds. Reprinted
with permission from Ref. 172. Copyright 2019 American Chemical Society.
54
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
dithianone cocrystal were less dependent on temperature fluctuation. molecular weight of the newly developed or developing pesticide com-
The cocrystal significantly reduced the sublimation of pyrimethanil at pounds, more and more AIs exist as solids under ambient conditions.
high temperatures. In contrast, formulation without cocrystal could have Besides, a major part of pesticide formulation products commonly used in
lost 70% of pyrimethanil four days after application of the product. agriculture, such as wettable powders and suspension concentrates,
Therefore, the cocrystal formulation can remain effective in hot weather contain solid AI particles. Therefore, in the foreseen future, more atten-
for months and thus be used for a wide variety of applications. tion on crystal engineering of pesticides is expected.
Essential oils: Essential oils (EOs) are a category of natural compo-
nents derived from plants. Most EOs are mainly composed of terpenes, 4.2. Patent protection
aromatic compounds, aliphatic compounds, nitrogen and sulfur com-
pounds, etc. These components usually show good biological activities. As one can tell, most of the cases mentioned above were recorded by
Currently, EOs have been shown to have a broad spectrum of activity published patents. Solid forms of pesticides, including polymorphs, hy-
against pests, mites, nematodes, weeds, plant pathogens and other drates, solvates, salts and cocrystals, represent new varieties of chemical
fungi.171 In addition, because it is derived from natural plants and is structures of the compound. Considering that the properties of a selected
non-toxic to non-target organisms, such environmentally friendly pesti- pesticide and the quality of the corresponding product can be tuned by
cides have a great potential to be applied in the control of crop diseases, crystal engineering, a new solid form of a pesticide could be both valu-
insect pests and sanitary pests. able and patentable.
However, EOs pesticides have some drawbacks. Low melting point Since the patent application protecting the chemical structure of a
and low water solubility remain enormous obstacles to the processing pesticide is typically filed in advance of the approval and market launch,
and spraying, but also high volatility and high degradability reduce their the exact period for which the innovator company will retain market
efficacy and persistence, thereby limiting the broad application of EOs exclusivity could be considerably less than 20 years. Therefore, for the
pesticides. Inspired by crystal engineering, researchers have developed innovator company, patents on novel crystal forms of a compound are
an alternative formulation of EOs pesticides cocrystals, which fixes vol- valuable in terms of extending the market exclusivity of a pesticide
atile liquid components into solid forms. A series cocrystals of eugenol product. Conversely, follow-up companies can also use the patents on
(EUG), thymol (THY) and carvacrol (CAR) were developed with six novel crystal forms to join the exclusive market after the expiration of the
different co-formers (phenazine, PHE; hexamethylenetetramine, HMT; compound patents.
isonicotinamide, INA; pyrazine, PYR; 2,3,5,6-tetramethylpyrazine, TMP;
2,3-dimethylquinoxaline, DMQ), as shown in Fig. 29 and Fig. 30.172,173 5. Outlook
The results of physical properties tests showed that cocrystals could
regulate the environmental release of EOs, that is, reducing the acute There is no doubt that the crystal engineering study of pesticides has
response and achieving a more persistent release at room temperature. drawn on experience developed in the pharmaceutical industry. How-
Notably, TMP-THY 1:1 cocrystal can convert to TMP-THY 1:2 cocrystal, ever, applications for pesticides and drugs are significantly different.
providing an attractive possibility of controlled release of more AI.173 When oral doses are taken by patients, the microcrystals of APIs
Moreover, CAR-HMT and EUG-HMT cocrystals exhibited increased water dissolve in the digestive system. Therefore, for APIs, the solubility and
solubility compared to pure EOs.172 The results of bioassays exhibited dissolution modification, which are directly related to the bioavailability
significant improvements of antibacterial and antifungal efficacy in the of the compound, have been one of the main targets of crystal engi-
treatments involving cocrystals compared to the treatments involving neering study.
pure EOs. For pesticides, the most frequently used pesticide products are for-
As mentioned above, cocrystal strategy has been applied as a mulations for mixing with water and then applying as sprays. Therefore,
powerful tool for improved the physical and chemical stability of tech- when pesticides are sprayed on plants, the microcrystals of pesticide will
nical materials or AIs in formulation. Similar examples of pendimetha- have to stay on the surface of leaves or in the environment for a certain
lin,78 triazole fungicides,174,175 and sulfentrazone and triazinone amount of time, which means the microcrystals may be exposed to a
herbicides176 could be found in the literature. more complex environment, such as sunlight and rainfall, than just dis-
solving in the digestive juices as their pharmaceutical counterparts.
4. Summary The differences in application scenarios lead to new questions that
need to be answered by future research in the crystal engineering of
4.1. The utility of crystal engineering in pesticides pesticides.
It is demonstrated in this section that the solid forms may have a great 1. Photostability: Since the pesticides need to be exposed to direct
impact on the physicochemical properties of a pesticide, including sunlight, can the crystal engineering strategy help improve the pho-
melting point, aggregation and recrystallization tendency, water solubi- tostability of pesticides?
lity, chemical stability, hygroscopicity and even bioactivity. Therefore, 2. Adhesive ability: Under rainfall, will a novel solid form of pesticides
since the 1980s, crystal engineering has been an effective strategy have a better adhesive ability to the leaves so that less AIs are flushed
applied by large agrochemical companies to overcome the shortage of into the environment?
selected pesticide products. 3. Bioavailability: Though the impact of solid forms on bioactivity was
It is worth noting that, normally, there is no “perfect” solid form for reported, there is still lacking a common understanding in terms of
all pesticides. In terms of solubility and bioactivity, amorphous solid may the correlation between solid forms and bioavailability. One possible
show the best performance. However, the metastable nature of amor- reason is that the correlation between bioactivity or bioavailability
phous solid always leads to a high tendency of aggregation and recrys- and solid forms is much less frequently studied. Besides, the targets of
tallization, as well as weak chemical stability. Therefore, for most pesticides are more complex, including insects, weeds and fungi.
commercialized pesticide formulation products, it is rare to choose an Thus, it is hard to draw a universal conclusion with solid evidence and
amorphous solid as the first option. Fortunately, crystal engineering sound reasoning. This vacuum in knowledge implies that the research
strategies, including amorphous solids, polymorphs and cocrystals, pro- on the correlation between solid forms and bioavailability, as well as
vide “tools” to tune the properties of pesticides at different levels ac- the essential property of pesticides will be one of the most important
cording to the specific requirement of the processing, storage and challenges that need to be addressed in the future.
application scenario of the given pesticide product. 4. Crystallization behavior of pesticides on the biointerface: For
With the increasing complexity of the molecular structure and solution formulations containing no solids, the crystals of pesticides
55
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
Fig. 30. Schematic representation of the cocrystals synthesized from the combination of two constituents of essential oils and four co-formers. Thumbnail of the
corresponding crystalline structures showing the core EO-co-former assemblies. Blue dotted lines represent intermolecular H-bonds. Reprinted with permission from
Ref. 173. Copyright 2022 American Chemical Society.
56
X. Niu et al. Advanced Agrochem 1 (2022) 39–60
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