FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
COMPLETE SPECIFICATION
(See Section 10; rule 13)
Tiltle: Process for manufacturing D-Trans Allethrin
Applicant: SHOGUN ORGANICS LIMITED, 504, Samartha Vaibhav, Lokhandwala Complex, Off.Link Road, Andheri (W), Mumbai-400 053, Maharashtra, India, An Indian company.
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

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The present invention relates to the process for manufacturing d-Trans Allethrin.
Background and Prior Art:
Process synthesis of manufacture of" d-trans Allethrin " technical. The product is used as an active ingredient in mosquito repellant and control products . The process includes the esterification of an optically active alcohol with an acid chloride . The ester so formed has high insect repellant properties . This special synthesis route has been developed for specific use in household insecticide products as an Active ingredient against mosquitoes
The synthesized pyrethroid can be used in specific formulations in India as approved by the Insecticide Registration Committee. This can work as an effective solution to mosquito control. The special 6 step process of synthesis of D-trans allethrin technical is highly effective method of manufacture of this high efficacy , low human toxicity product. The chemical synthesis route has been invented by us with complete study on it effects on mosquitoes . Effective isomers are formed which give maximum repellant and knockdown effect to

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mosquitoes. The synthesis process can be replicated in small Laboratory scale experiments as well as large commercial scale production . It gives consistent results. The process design is used to manufacture a chiral pyrethroid insecticide. Its is effective to kill or repel mosquitoes and other insects. It is a yellow to dark brown viscous liquid. The effective process and six step synthesis process would give results of Minimum 93 % pure content. Other related allowed impurities are formed .
Object of invention:
D trans allethrin is also assumed that its characteristic knockdown and insect toxicity are associated to a greater or lesser degree with certain of the several isomers present. To establish quantitatively their relative insect toxicity, it would be necessary to prepare and test all the optical isomers.
D - Allethrolone (72:21 ), is being used for the synthesis of this pyrethroid . The process steps are taken from the base of Ethyl

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Chrysanthemate. The first five steps signify the preparation of Chrysanthemic Acid Chloride. Chrysanthemic acid is treated with thionyl chloride to form the Acid chloride.
This is reacted with the Allethrolone , along with Pyridine and toluene and added to the reaction. The stepwise manufacturing process synthesis of D-trans Allethrin has been stated.
Process of manufacture:
Step I
d-trans Ethyl chrysanthemate is charged into the reactor along with
methyl alcohol, solid sodium hydroxide and water
Step II
The reactants are refluxed until sapenification is complete and the
menthanol ( methyl alcohol) is distilled off at atmospheric pressure
Step III
The contents are cooled to 20 degrees Celsius and the material is
acidified by the addition of sulphuric acid . The acid converts the
sodium chrysanthemate to d-trans chrysanthemic acid
Step IV

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Petroleum Ether is added . The d-trans chrysanthemic acid goes into the petroleum layer, while sodium sulphate remains dissolved in the water layer. The two phases are allowed to settle for 1 hour. Later the water layer is drained to the effluent tank and the organic layer goes to the reactor
StepV
The solvent is distilled to obtain pure acid . The acid is treated with thionyl chloride to make chrysanthemic acid chloride , which is dissolved , in a suitable solvent.
Step VI
d-Allethrolone ( 72:21 ), pyridine and toluene are added to the reactor. The acid chloride is added gradually to the reaction mass. The reaction occurs forming d-trans Allethrin. Hydrogen chloride gas is scrubbed using a caustic scrubber. D-trans allethrin thus formed remains in the organic layer. The solvent is distilled off and pure product of required quantity is obtained

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We Claim:
1. Process of manufacturing d-trans Allethrin comprising of following steps:
a) charging d-trans Ethyl chrysanthemate into a reactor at a temperature of 5 to 10 degrees C along with 325 grams methyl alcohol, solid sodium hydroxide and water.
b) subjecting reactants for saponification and distilled off methyl alcohol at atmospheric pressure of 4kg
c) cooling of contents at 20°c and further acidification with sulphuric acid wherein sodium chrysanthemate is converted into d-trans chrysanthemic acid,
d) adding 1.70 kgs quantity of petroleum ether which forms two layers petroleum layer containing d-trans chrysanthemic acid and water layer with dissolved sodium sulphate.
e) allowing two layers to settle for 1 hour, water layer is drained to effluent tank and d-trans chrysanthemic acid remains in the reactor,
f) carrying distillation of d-trans chrystanthemic acid at 20 degrees
g) treating d-trans chrysanthemic with 150 grams thiunyl chloride, thus forming d-trans chrysanthemic acid chloride which further is dissolved in N-heptane solvent.

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h) adding 540 grams d-allethrolne(72:21) 230 grams pyridine and 600 grams toluene with d-trans chrysanthanic acid chloride in a reactor gradually resulting to desired d-trans allethrin.
2. The process of manufacturing d-trans allethrin as claimed in claim 1 wherein hydrogen chloride gas is scrubbed using caustic scrubber directly.
3. The process of manufacturing d-trans allethrin as claimed in claim 1 & 2 wherein the organic layer containing d-trans allethrin is distilled off to yield desired end product.

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ABSTRACT
D trans allethrin is also assumed that its characteristic knockdown and insect toxicity are associated to a greater or lesser degree with certain of the several isomers present. To establish quantitatively their relative insect toxicity, it would be necessary to prepare and test all the optical isomers.
D - Allethrolone ( 72:21 ), is being used for the synthesis of this pyrethroid . The process steps are taken from the base of Ethyl Chrysanthemate. The first five steps signify the preparation of Chrysanthemic Acid Chloride. Chrysanthemic acid is treated with thionyl chloride to form the Acid chloride.
This is reacted with the Allethrolone , along with Pyridine and toluene and added to the reaction. The stepwise manufacturing process synthesis of D-trans Allethrin has been stated.