Isoprothiolane Manufacturing Plant Project Report 2025: Market by Region, Market by Application, Key Players, Pre-feasibility, Capital Investment Costs, Production Cost Analysis, Expenditure Projections, Return on Investment (ROI), Economic Feasibility, CAPEX, OPEX, Plant Machinery Cost

Isoprothiolane Manufacturing Plant Project Report 2025: Cost Analysis, ROI, and Feasibility Insights

Isoprothiolane Manufacturing Plant Report by Procurement Resource thoroughly focuses on every detail that encompasses the cost of manufacturing. Our extensive cost model meticulously covers breaking down Isoprothiolane plant capital cost around raw materials, labour, technology, and manufacturing expenses. This enables precise cost structure optimisation and helps in identifying effective strategies to reduce the overall Isoprothiolane manufacturing plant cost and the cash cost of manufacturing.

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Isoprothiolane is an organosulfur compound that functions as a systemic fungicide. It appears as a colourless crystalline solid. Isoprothiolane is primarily valued for its effectiveness in controlling rice blast disease (Magnaporthe oryzae), a devastating fungal disease affecting rice crops globally. It also exhibits insecticidal activity against planthoppers and is used in various agricultural settings.
 

Industrial Applications

• Agriculture (Dominant Use - 100% of applications):
  • Rice Blast Control: Its primary application is as a systemic fungicide for controlling rice blast disease, which is a major threat to rice production worldwide. Isoprothiolane inhibits the biosynthesis of melanin in fungi, interfering with appressorium formation and preventing infection.
  • Insecticidal Activity: Exhibits insecticidal activity against various rice pests, particularly planthoppers (e.g., brown planthopper, white-backed planthopper). This dual action provides comprehensive crop protection.
  • Seed Treatment: Can be used for seed treatment to protect rice seedlings from early fungal infections.
  • Integrated Pest Management (IPM): Often incorporated into Integrated Pest Management strategies for rice cultivation, providing a broad-spectrum solution.
  • Crop Yield Enhancement: By effectively controlling fungal diseases and insect pests, Isoprothiolane helps to maximise rice yields and ensure food security in major rice-producing regions.
     

Top 5 Industrial Manufacturers of Isoprothiolane

• Sumitomo Chemical Co., Ltd. (Japan)
• Jiangsu Huifeng Agrochemical Co., Ltd. (China)
• Anhui Fengle Agrochemical Co., Ltd. (China)
• UPL Ltd. (India) (through various formulations)
• Sichuan Lier Chemical Co., Ltd. (China)
   

Feedstock for Isoprothiolane

• Diisopropyl Malonate (C9H16O4) (Major Feedstock):
  • Source: Diisopropyl malonate is an ester synthesised from malonic acid and isopropanol. Malonic acid can be produced from chloroacetic acid, and isopropanol is derived from propylene (a petrochemical).
  • The price of diisopropyl malonate is influenced by the cost of its precursors, particularly isopropanol (linked to crude oil/natural gas prices via propylene) and malonic acid (linked to chloroacetic acid). As a speciality ester, its availability can be influenced by specific supplier capacities. Efficient industrial procurement of high-purity diisopropyl malonate is vital for a competitive cost model for Isoprothiolane manufacturing, directly impacting the cash cost of production and the overall isoprothiolane plant capital cost.
• Carbon Disulfide (CS2) (Major Feedstock):
  • Source: Carbon disulfide is primarily produced industrially by reacting methane (from natural gas) or charcoal with sulfur.
  • The cost of carbon disulfide is influenced by natural gas prices (for methane) and elemental sulfur prices. Demand from its major end-use industries (e.g., rayon fibre, cellophane, rubber chemicals, thiocarbamate pesticides) impacts its availability and cost. Carbon disulfide is highly flammable and toxic, requiring stringent safety measures, specialised handling, and storage, which add to industrial procurement complexities and overall manufacturing expenses.
• Sodium Hydroxide (NaOH) (Major Reagent):
  • Source: Sodium hydroxide (caustic soda) is predominantly produced through the chlor-alkali process (electrolysis of brine).
  • The cost of sodium hydroxide is significantly influenced by electricity prices (a major input for chlor-alkali electrolysis) and the global demand for its co-product, chlorine.
• Dichloroethane (DCE) (C2H4Cl2) (Solvent/Reagent):
  • Source: Dichloroethane (specifically 1,2-dichloroethane) is a chlorinated hydrocarbon primarily produced by the oxychlorination or direct chlorination of ethylene (a petrochemical).
  • Its price is linked to ethylene costs (from crude oil/natural gas). Dichloroethane is volatile and toxic, requiring careful handling and stringent safety protocols, which adds to industrial procurement costs.
     

A thorough understanding of the feedstock dynamics, especially the dependence on diverse petrochemical and energy-intensive intermediates, as well as the intricate handling and stringent safety requirements associated with hazardous materials like carbon disulfide and dichloroethane, is essential for accurately estimating the should-cost of production and evaluating the overall economic viability of Isoprothiolane manufacturing.
 

Market Drivers for Isoprothiolane

• Global Rice Production & Food Security: The continuous increase in global population drives an escalating demand for rice, a staple food for a large portion of the world. Isoprothiolane's effectiveness in controlling rice blast disease and planthoppers directly contributes to higher rice yields and ensures food security in major rice-growing nations, fueling its demand.
• Prevalence of Rice Blast Disease: Rice blast, caused by Magnaporthe oryzae, remains one of the most destructive diseases of rice worldwide, capable of causing significant yield losses. The persistent threat of this disease ensures a continuous need for effective fungicides like Isoprothiolane in rice cultivation areas.
• Integrated Pest Management (IPM) Strategies: Isoprothiolane's dual fungicidal and insecticidal activity makes it a valuable tool in integrated pest management strategies for rice. Its ability to address multiple pest challenges with one application offers efficiency and cost savings to farmers, driving its adoption.
• Economic Viability for Farmers: Isoprothiolane provides a cost-effective solution for protecting rice crops from significant yield losses due to fungal diseases and insect infestations. Its application helps farmers achieve better returns on investment, supporting its market demand.
• Climate Change Impacts: Changing climate patterns can influence pest and disease prevalence. As new challenges emerge or existing ones intensify due to environmental shifts, the demand for effective crop protection tools like Isoprothiolane may be sustained or even increase in vulnerable regions.
• Regional Market Drivers: Isoprothiolane's global market is overwhelmingly concentrated in the Asia-Pacific region, which accounts for more than 90% of consumption due to its massive rice production, prevalence of pests and diseases, and the push for agricultural modernisation and food security, thereby driving strategic manufacturing investments. In Latin America, demand is modest but growing as rice cultivation expands and effective crop protection is sought. Europe's use is limited to niche rice-growing areas in the south, while North America's market is negligible due to the lack of regulatory approvals for major crops.
   

Capital Expenditure (CAPEX) for an Isoprothiolane Manufacturing Facility

• Reaction Section Equipment:
  • Condensation Reactors: Primary investment in robust, agitated, jacketed reactors, typically constructed from stainless steel or specialised alloys (e.g., Hastelloy) capable of handling diisopropyl malonate, carbon disulfide, sodium hydroxide, and dichloroethane.
• Raw Material Storage & Feeding Systems:
  • Diisopropyl Malonate Storage: Tanks for liquid diisopropyl malonate, with precision metering pumps for controlled addition.
  • Carbon Disulfide (CS2) Storage & Delivery: Highly specialised, sealed, explosion-proof, and often refrigerated storage tanks for carbon disulfide due to its extreme flammability and toxicity.
  • Sodium Hydroxide (NaOH) Storage: Corrosion-resistant bulk storage tanks for concentrated sodium hydroxide solution, with precision metering pumps for controlled addition.
  • Dichloroethane (DCE) Storage: Sealed storage tanks for dichloroethane, with appropriate safety measures for volatile, flammable, and toxic liquids. Precision metering pumps.
  • Phase-Transfer Catalyst Storage & Dosing: Small, dedicated storage and precise dosing systems for the phase-transfer catalyst (e.g., quaternary ammonium chloride).
• Product Separation & Purification:
  • Quenching/Neutralisation Section: Vessels for cooling and neutralising the reaction mixture post-reaction, often involving water washes to remove salts and by-products.
  • Liquid-Liquid Separators/Decanters: For efficiently separating the organic Isoprothiolane layer from any aqueous phases after washing steps.
  • Vacuum Distillation Columns: Multiple stages of high-efficiency vacuum distillation columns are crucial for purifying Isoprothiolane.
  • Crystallisers (if solid product): If crystallisation is used for final purification, specialised crystallisers (e.g., cooling crystallisers) are used to produce high-purity crystalline Isoprothiolane.
  • Filtration Units: Industrial filter presses or centrifuges for efficiently separating the solid Isoprothiolane product from the mother liquor.
  • Washing Systems: Dedicated tanks and pumps for thoroughly washing the filtered Isoprothiolane cake with purified water or a solvent.
  • Drying Equipment: Specialised industrial dryers (e.g., vacuum tray dryers, fluid bed dryers, rotary dryers) for gently removing residual solvent and moisture from the purified Isoprothiolane powder/crystals, preserving its stability and quality.
• Solvent Recovery & Recycling System:
  • This includes dedicated distillation columns, condensers, and solvent storage tanks to minimise solvent losses, reduce environmental impact, and significantly lower operational costs.
• Off-Gas Treatment & Scrubber Systems:
  • This involves multi-stage wet scrubbers (e.g., acidic scrubbers for any amine fumes, caustic scrubbers for acidic gases like HCl or H2S if formed, as well as for carbon disulfide vapours) to capture and neutralise volatile organic compounds (VOCs) and hazardous gases released.
• Pumps & Piping Networks:
  • It consists of an extensive network of robust, chemical-resistant pumps (e.g., magnetically driven pumps to minimise leaks, specialised for highly flammable and toxic liquids) and piping (e.g., stainless steel, PTFE-lined, specialised alloys) suitable for safely transferring highly flammable, toxic, and corrosive raw materials and reaction mixtures throughout the process.
• Product Storage & Packaging:
  • Sealed, cool, and dry storage facilities for purified Isoprothiolane powder/crystals. Automated packaging lines for filling into various-sized containers (e.g., bags, drums, bulk bags) for agricultural use.
• Utilities & Support Infrastructure:
  • Steam generation (boilers) for heating reactors and distillation reboilers. Robust cooling water systems (with chillers/cooling towers) for reaction temperature control, condensation, and crystallisation.
• Instrumentation & Process Control:
  • It includes a sophisticated Distributed Control System (DCS) or advanced PLC system with Human-Machine Interface (HMI) for automated monitoring and precise control of all critical process parameters (temperature, pressure, flow rates, pH, reactant ratios, distillation profiles).
• Safety & Emergency Systems:
  • Consists of comprehensive multi-point leak detection systems (for CS2, DCE), emergency shutdown (ESD) systems, fire detection and suppression systems (e.g., foam, CO2, inert gas flooding due to CS2's extreme flammability), chemical spill containment, emergency showers/eyewash stations, and extensive personal protective equipment (PPE) for all personnel, including specialised chemical-resistant suits and respiratory protection.
• Laboratory & Quality Control Equipment:
  • A fully equipped analytical laboratory with advanced instruments such as High-Performance Liquid Chromatography (HPLC) for precise purity and impurity analysis, Gas Chromatography (GC) for residual solvents, Karl Fischer titrators for moisture content, melting point apparatus, and particle size analysers.
• Civil Works & Buildings:
  • Costs associated with land acquisition, site preparation, foundations, and construction of specialised reactor buildings (often with robust ventilation and explosion-proof design), distillation and purification sections, dedicated raw material storage facilities (especially for highly hazardous materials), product warehousing, administrative offices, and utility buildings.
     

Operational Expenditures (OPEX) for an Isoprothiolane Manufacturing Facility

• Raw Material Costs (Highly Variable): It includes the purchase price of diisopropyl malonate, carbon disulfide (CS2), sodium hydroxide (NaOH), dichloroethane (DCE), and the phase-transfer catalyst.
• Utilities Costs (Variable): Includes electricity consumption for agitation, pumps, distillation columns (reboilers, vacuum systems), and control systems. Energy for heating (e.g., reaction, distillation) and cooling (e.g., reaction temperature control, condensation) also contribute substantially.
• Labour Costs (Semi-Variable): Wages, salaries, and benefits for the entire plant workforce, including highly trained process operators (often working in shifts), chemical engineers, maintenance technicians, and quality control personnel.
• Maintenance & Repair Costs (Fixed/Semi-Variable): Ongoing expenses for routine preventative and predictive maintenance programs, calibration of sophisticated instruments, and proactive replacement of consumable parts (e.g., pump seals, valve packings, reactor linings, distillation column packing).
• Catalyst Costs (Variable): Expense associated with the purchase of fresh phase-transfer catalyst and any associated make-up catalyst.
• Chemical Consumables (Variable): Costs for inert gases (e.g., nitrogen for blanketing), neutralising agents for scrubbers, water treatment chemicals, and laboratory consumables for ongoing process and quality control.
• Waste Treatment & Disposal Costs (Variable): These are often very significant expenses due to the generation of various hazardous liquid wastes (e.g., aqueous washes containing salts, residual organics, spent solvents), and gaseous emissions (e.g., CS2 vapours, DCE vapours, HCl).
• Depreciation & Amortisation (Fixed): These are non-cash charges that gradually distribute the initial capital investment (CAPEX) across the expected useful lifespan of the plant's assets.
• Quality Control Costs (Fixed/Semi-Variable): Expenses for the reagents, consumables, and labour involved in continuous analytical testing to ensure the high purity, specific isomer content (if applicable), and active ingredient concentration of the final Isoprothiolane product.
• Administrative & Overhead (Fixed): General business expenses, including plant administration salaries, comprehensive insurance premiums (often higher due to hazardous materials and processes), property taxes, and ongoing regulatory compliance fees specific to agrochemical manufacturing.
• Interest on Working Capital (Variable): The cost of financing the day-to-day operations, including managing raw material inventory (especially high-value speciality intermediates and hazardous materials) and finished product inventory, impacts the overall cost model.

Meticulous tracking and optimisation of both fixed and variable costs are essential to reduce the cost per metric ton (USD/MT) and to maintain the economic viability and long-term competitiveness of Isoprothiolane production.
 

Manufacturing Process of Isoprothiolane

This report comprises a thorough value chain evaluation for Isoprothiolane manufacturing and consists of an in-depth production cost analysis revolving around industrial Isoprothiolane manufacturing.

• Production via Chemical Synthesis: The industrial manufacturing process of Isoprothiolane involves a multi-component chemical synthesis to form its characteristic dithiolane ring structure. The key feedstock for this process includes: diisopropyl malonate (C9H16O4), carbon disulfide (CS2), sodium hydroxide (NaOH), and dichloroethane (C2H4Cl2).
   

The synthesis begins with the chemical reaction of diisopropyl malonate and carbon disulfide with sodium hydroxide (NaOH) in the presence of dichloroethane, which acts as a solvent and a reactant to form the ring structure. A chloride (e.g., a quaternary ammonium salt) is often used as a phase-transfer catalyst to facilitate the reaction between aqueous sodium hydroxide and the organic reactants. This reaction sequence involves the formation of an intermediate, which then cyclises with the dichloroethane to form the dithiolane ring system, ultimately resulting in the formation of Isoprothiolane as the final product. After the reaction, the crude product mixture undergoes purification steps, which involve quenching, washing to remove salts and by-products, and subsequent purification techniques such as crystallisation, filtration, and drying to obtain the high-purity crystalline Isoprothiolane product.
 

Properties of Isoprothiolane

Physical Properties:

• Molecular Formula: C12H18O4S2
• Molar Mass: 290.4 g/mol
• Melting Point: 54-55 degree Celsius (129-131 degree Fahrenheit). It is a solid at room temperature.
• Boiling Point: 166-167 degree Celsius at 1.0 mmHg (sublimes easily).
• Density: 1.25 g/cm3 (solid, at 20 degree Celsius).
• Appearance: Colourless crystalline solid.
• Odour: Faint, characteristic odour.
• Solubility: Sparingly soluble in water (e.g., 48 mg/L at 20 degree Celsius). Readily soluble in many organic solvents such as acetone, methanol, benzene, chloroform, and xylene.
   

Chemical Properties:

• pH (of aqueous suspension): An aqueous suspension of Isoprothiolane is near-neutral.
• Reactivity: Isoprothiolane is generally stable under normal conditions. It can undergo hydrolysis under extreme pH conditions (strong acids or bases) or photolysis in the presence of UV light.
• Mechanism of Action (Fungicidal): Isoprothiolane primarily acts as a melanin biosynthesis inhibitor. It interferes with the formation of melanin in the cell walls of fungi (like Magnaporthe oryzae), which is essential for the formation of the appressorium (a specialised infection structure). By inhibiting melanin, it prevents the fungus from penetrating plant tissues, thus controlling the disease.
• Mechanism of Action (Insecticidal): Its insecticidal activity against planthoppers is linked to its ability to disrupt neurotransmission or energy metabolism in the insects, though the exact mechanism can be complex.
• Stability: Stable to heat and light under normal conditions. It is also stable in acidic and neutral media.
• Environmental Fate: Its persistence in soil and water varies depending on environmental conditions (pH, microbial activity, light).
   

Isoprothiolane Manufacturing Plant Report provides you with a detailed assessment of capital investment costs (CAPEX) and operational expenses (OPEX), generally measured as cost per metric ton (USD/MT). This approach ensures that your investment decisions are aligned with the latest industry standards and economic feasibility metrics, enhancing your manufacturing efficiency and financial planning.

Apart from that, this Isoprothiolane manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Isoprothiolane manufacturing plant and its production process, and also by helping you with an in-depth supplier database. This report provides exclusive insights into the best manufacturing practices for Isoprothiolane and technology implementation costs. This report also covers operational cash flow, fixed and variable costs, and detailed break-even point analysis, ensuring that your manufacturing process is not only efficient but also economically viable in the competitive market landscape.

In addition to operational insights, the Isoprothiolane manufacturing plant report also comprehensively focuses on lifecycle cost analysis, maintenance costs, and energy consumption costs, which are critical for maintaining long-term sustainability and profitability. Our manufacturing cost analysis extends to include regulatory compliance costs, inventory holding costs, and logistics and distribution costs, providing a holistic view of the potential expenses and savings.

We at Procurement Resource ensure that this report is not only cost-efficient, environmentally sustainable, and aligned with the latest technological advancements but also that you are equipped with all necessary tools to optimise supply chain operations, manage risks effectively, and achieve superior market positioning for Isoprothiolane.
 

Key Insights and Report Highlights

Key Questions Covered in our Isoprothiolane Manufacturing Plant Report

• How can the cost of producing Isoprothiolane be minimised, cash costs reduced, and manufacturing expenses managed efficiently to maximise overall efficiency?
• What is the estimated Isoprothiolane manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up an Isoprothiolane manufacturing plant, and how do these investments affect economic feasibility and ROI?
• How do we select and integrate technology providers to optimise the production process of Isoprothiolane, and what are the associated implementation costs?
• How can operational cash flow be managed, and what strategies are recommended to balance fixed and variable costs during the operational phase of Isoprothiolane manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Isoprothiolane, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Isoprothiolane manufacturing, and which production efficiency metrics are critical for success?
• What strategies are in place to optimise the supply chain and manage inventory, ensuring regulatory compliance and minimising energy consumption costs?
• How can labour efficiency be optimised, and what measures are in place to enhance quality control and minimise material waste?
• What are the logistics and distribution costs, what financial and environmental risks are associated with entering new markets, and how can these be mitigated?
• What are the costs and benefits associated with technology upgrades, modernisation, and protecting intellectual property in Isoprothiolane manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Isoprothiolane manufacturing?