Sunscreen stands as a cornerstone in protecting the skin from the sun's harmful rays, impacting not only cosmetic concerns but also overall skin health. It is not surprising how brands always seek to launch their own sunscreen as the demand for sun protection grows. However, the process of formulating a sunscreen is a complicated one and requires knowledge in various areas to ensure a smooth process. In this expert guide, we will walk through some of the important points for consideration when manufacturing sunscreen and ensuring it meets safety standards. We will also address specific considerations such as halal certification and packaging choices.

Types of sunscreen

Sunscreens are classified into three categories: physical sunscreens, chemical sunscreens and hybrid sunscreens. The choice of the type of sunscreen for your brand will depend on your target audience and their common skin concerns, your brand philosophy, the type of the sunscreen product you want to create (cream, stick(balm) or spray), as well as the regulatory requirements of the country in which it will be sold.

Physical Sunscreens (aka Mineral Sunscreens)

Physical sunscreens use zinc oxide or titanium dioxide, both recognized as safe and effective by the US FDA, to create a physical barrier on the skin that reflects UV rays away from the skin. These ingredients tend to be less irritating than chemical ones. This type of sunscreen also help ward off UVA-related skin damage, such as hyperpigmentation, breakdown of collagen which leads to wrinkles and photoaging. It is also often recommended for people with sensitive skin types, including acne-prone skin.

One downside of mineral sunscreens is that they can be chalky and difficult to spread, leaving behind a noticeable white cast on the skin that looks even more apparent on darker skin tones. This type of sunscreen is also not always water-resistant, hence requires reapplication throughout the day.

Chemical Sunscreens

Chemical sunscreens contain active ingredients that absorb UV rays before they reach the deeper layers of your skin. Some of these chemical UV filters are oxybenzone, avobenzone, octisalate, octocrylene, homosalate and octinoxate. This type of sunscreen typically does not leave a visible film layer or a white case on the skin, making it a perfect option for a wider range of skin tones. Chemical sunscreens also tend to be more easily absorbed by the skin, leaving no stickiness or oiliness.

A potential drawback of chemical sunscreens is that they can be irritating to people with sensitive skin or skin conditions such as rosacea and acne.

Hybrid Sunscreens (aka Combination Sunscreens)

Hybrid sunscreens are sunscreens that contain both physical and chemical sunscreen actives, which means they are a combination of both UV-reflective properties of physical actives and the UV-absorbing properties of chemical actives in one formula. It is believed that combining the two properties of sunscreen makes it more effective than either type on its own as it provides a broader sense of defense against UV rays.

The most important thing in sunscreen manufacturing

Formulating your own sunscreen from scratch is a great way to offer innovative solutions for your customers or target audience. However, it's important to keep in mind that in the creation of a sunscreen formulation, the most important aspect to consider is safety and effectiveness. Opting for well-established and FDA-approved sunscreen actives, such as zinc oxide or titanium dioxide, is a great way to ensure both safety and efficacy. These ingredients offer broad-spectrum protection and are generally recognized as safe and effective for use in sunscreens. At the same time, different countries have different regulations regarding the safe use of sunscreen ingredients, therefore it is crucial to understand the regulations of the country you're planning to sell to. If you're combining sunscreen agents, you may also need to check for patents covering formulation techniques and blends. 

Achieving the desired SPF in sunscreen formulation

Balancing the formulation to achieve the desired sun protection factor (SPF) is another critical factor. The proportion of active ingredients, emollients, and other components must be carefully calibrated to meet the specified SPF while maintaining a pleasant texture and ease of application. SPF testing is also relatively costly and adds to your manufacturing expense if you're going for the custom formulation option instead of a private/white labeling option. To achieve the desired SPF, you will also need to consider the permitted concentration of ingredients, the spreadability and/or aesthetics. Due to the difficulties in balancing the aspects of formula spreadability, stability, safety and regulations, smaller brands or beauty startups tend to prefer private/white labeling sunscreen formulas for their brands.

Getting your sunscreen product certified safe

While achieving a high SPF rating is crucial, the safety of sunscreen products is equally paramount. Chemical UV agents have the potential to cause irritation, making it essential to test sunscreen products for possible reactions. The use of fragrances and preservatives in combination with UV agents in a single formula may also cause irritant reactions in the skin. Generally, the higher the percentage used of a chemical UV agent, the greater its potential to cause skin irritations.

If you're planning to sell in the US for example, you should know that the sunscreen products are regulated by the US FDA as drugs. Therefore, sunscreen manufacturers (domestic or foreign) must comply with all OTC drug requirements, including cGMP (Current Good Manufacturing Practice), establishment registration, drug label compliance and more. If you're using titanium dioxide or zinc oxide in your formula, they should also not exceed 25%. 

Understanding regional regulations is crucial when developing and marketing sunscreen products. Each region has its own set of standards and requirements. Here's a differentiation chart to highlight key aspects of sunscreen regulations in Australia, the USA, and Southeast Asia:

Consider halal certifications for your sunscreen product

Halal certifications are not mandatory for sunscreen products. However, it may appeal to Muslim consumers and you may consider getting your sunscreen product certified halal if you're targeting Muslim consumers. For halal certification, careful consideration of ingredient sourcing is necessary. A formula's halal status is determined by evaluating the source of each ingredient and ensuring adherence to Islamic slaughtering standards. And for many Muslim consumers it can be difficult to find sunscreen products that are permissible to use according to Islamic law. Therefore, many new brands and beauty startups are aiming to create halal sunscreens for their target audience. 

If all of your ingredients are from plants or animals that have been slaughtered according to Islamic law, then you should be good on your way to certifying your product as being halal!

Choosing the right packaging for your sunscreen product

When designing the packaging for your cosmetic brand's sunscreen, think about incorporating tubes for flexibility, spray bottles for rapid application, sticks for accuracy, pump bottles for cleanliness, and pouches for environmental sustainability. 

Packaging is also an important aspect as it serves as a protective shield, safeguarding the sunscreen from external elements such as air, light, and moisture, guaranteeing its optimal functionality upon application.

Each type has its own advantages and disadvantages. Tubes provide a versatile and convenient application, allowing users to control the amount of product dispensed and facilitating easy portability. Spray bottles offer a quick and efficient method for application, ensuring even coverage, especially in larger areas. Sticks emerge as a precise choice, enabling users to target specific areas with accuracy, making them ideal for facial application or touch-ups. Pump bottles enhance hygiene by minimizing product contamination, offering a more controlled dispensing mechanism. 

Labelling considerations for sunscreens

When it comes to labels, there are several rules you need to follow. First and foremost, the label must be in English if you're selling in the United States as this is a requirement of the US Federal Food, Drug and Cosmetic Act (FD&C). Besides language, it is also generally required that the label be clear and easy to read; not only for you as the manufacturer but also for any customers who may buy your product. Product claims (such as broad spectrum SPF or any claims related to altering the structure of the skin or body) may also subject to local regulations of the country you're selling to. Finally, if there is any chance that the sunscreen could cause an allergic reaction for those who use it (even if this is unlikely), then warning labels are required by law.

It's more complicated than you think

Crafting your own sunscreen is a complex process that goes beyond mixing ingredients. It involves meticulous formulation, adherence to safety standards, and consideration of specific factors like halal certification and packaging choices. Whether you embark on creating your own formula or seek assistance through platforms like MAYK, understanding the nuances of sunscreen production is key to developing an effective and safe product for sun protection.

Conclusion

We hope we’ve been able to give you some insight into the complexities of creating your own sunscreen product. It may seem like a simple thing, but there are many factors involved in making a truly effective sunscreen product. Fo those seeking an easier way out, check out our Advanced Defense Hybrid Sunscreen on our private/white labeling catalog, where you can easily begin manufacturing with our formula and brand them as your own.

If you'd still like to formulate your own unique sunscreen but unsure of what to do, just send us an inquiry. Get in touch with us for a 1:1 consultation where we can explore your specific requirements, preferences, and goals in formulating a sunscreen product for your brand. Your brand deserves the finest. :)