Abstract: A process and apparatus are disclosed for producing polymerized beads containing actives such as perfumes and pesticides, by forming droplets from a solution of monomers and the actives. The solution is subjected to ultraviolet light to initiate polymerization. The droplets are caused to fall through a reaction vessel as polymerization continues so as to polymerize substantially spherical beads containing the actives. In one embodiment, the droplets are irradiated as they fall through the reaction vessel. In a second embodiment, the solution is irradiated prior to droplet formation and the fall. The beads are collected and can be cured if necessary. The process is preferably performed in an inert gas environment which most preferably is nitrogen. A nitrogen stream can serve as a carrier for the monomers and active ingredients. The nitrogen environment is maintained in the reaction vessel, and in the curing structure, if present.

Abstract: A process and apparatus are provided for producing polymerized plugs in which the polymerization starting materials are passed through heated reaction tubes by gravity feed. The polymerized rods so produced are cut into plugs and packaged for use. In an alternative embodiment, the polymerization starting materials are first encased within flexible sleeves, and the flexible sleeves are then passed through the heated tubes by gravity feed to form polymerized rods. Apparatus for performing the process includes at least one tube having an inlet opening and an outlet opening, the outlet opening being at a lower elevation than the inlet opening to provide for gravity feed through the tube, and structure to heat the tube. A cutting device cuts the polymerized rods into plugs as they exit the outlet opening.