26 Oct Sunscreen manufacturer: Next-generation formats beauty brands should watch
Sunscreen manufacturer: Next-generation formats beauty brands should watch
For established beauty brands and retailers, choosing the right sunscreen manufacturer is essential to transforming these concepts into commercially viable products.
The sunscreen market is evolving beyond traditional lotions and creams. Today’s beauty brands are exploring innovative formats that combine effective sun protection, lightweight textures, convenient application and skincare-inspired benefits.
Developing modern sun care formulations means balancing SPF performance, sensory experience, product stability, regulatory requirements and industrial scalability. Each new format introduces technical challenges that require specialized formulation and manufacturing expertise.
Discover five formats worth exploring and the key considerations behind their development.
Next-Generation sunscreen formats for beauty brands
1. SPF Sticks: Convenient Protection in a Solid Format
Sunscreen sticks are an attractive format for brands looking to combine portability, targeted application and a convenient user experience.
Their compact design makes them suitable for facial sun protection, outdoor activities and on-the-go routines.
However, developing a high-performance SPF stick requires careful formulation. Manufacturers must balance the solid structure with smooth application, uniform product distribution, stability and UV protection performance.
Anhydrous formulation expertise is particularly important, as the selection of waxes, emollients and UV filters directly influences the final product’s texture and functionality.
2. Lightweight Sunscreen Gels and Gel-Creams
Lightweight textures such as gels and gel-creams offer a fresh sensory experience, easy spreadability and a comfortable finish, making them interesting options for skincare-oriented sunscreen collections.
The technical challenge lies in combining these sensory characteristics with effective UV protection and formulation stability.
For brands developing daily-use sun care products, texture can be an important factor in encouraging consistent application.
3. Multifunctional Sunscreens: Skincare Meets SPF
Sun protection is increasingly integrated into everyday skincare routines.
This creates opportunities for brands to explore multifunctional sunscreen concepts that combine UV protection with additional cosmetic benefits.
Potential product concepts include:
- Moisturizing facial sunscreens.
- Tinted sunscreen formulations.
- Sunscreens with antioxidant ingredients.
- Lightweight SPF products with skincare-inspired textures.
Developing these formulations requires evaluating ingredient compatibility, product stability, SPF performance and the regulatory implications of proposed claims.
4. Biphasic Sunscreens: Innovative Textures and Application
Biphasic sunscreen formulations combine two phases that are mixed before application, offering a distinctive sensory and visual experience.
For beauty brands, this format provides opportunities for product differentiation through texture, appearance and packaging.
However, formulation development requires particular attention to UV filter distribution, phase compatibility, stability and consistent application.
Ensuring reliable protection performance is essential when translating a biphasic concept into a finished sunscreen product.
5. Sunscreen Sprays and Mists
Sprayable sunscreen formats offer convenient application, particularly for body care and outdoor sun protection products.
Their development involves specific technical considerations, including spray performance, application uniformity, packaging compatibility and product stability.
For products intended for the US market, the applicable FDA requirements for sunscreen dosage forms and product safety must also be considered.
Why Sunscreen Manufacturing Requires Specialized Expertise
Developing innovative sunscreen products is significantly more complex than creating an appealing texture.
A successful formulation must combine protection performance, product stability, consumer experience and manufacturing consistency.
- Balancing SPF performance and sensory experience. SPF performance must be validated through standardized testing methods, such as ISO 24444, which establishes the procedure for determining the sun protection factor (SPF) in vivo.
- Formulation Stability and Packaging Compatibility
- From Laboratory Development to Industrial Production
At Cosmewax, we help established beauty brands and retailers turn innovative sun care concepts into market-ready products.
As an experienced European sunscreen manufacturer, we combine formulation expertise, advanced manufacturing capabilities and regulatory knowledge to support every stage of product development.
From SPF sticks and lightweight gel-creams to multifunctional sunscreens, biphasic formulations and sprays, our sun care portfolio offers a wide range of possibilities to meet evolving market demands.
With particular expertise in anhydrous formulations and solid formats, we provide flexible manufacturing solutions, from existing formulations to fully customized product development, backed by industrial scalability and consistent quality standards.
Explore our Sun Care Portfolio to discover the formats and formulation possibilities available for your brand.
Beauty brands should consider formulation expertise, manufacturing capacity, quality certifications, packaging capabilities and knowledge of the regulatory requirements applicable to their target markets.
Formats worth exploring include SPF sticks, lightweight gels, gel-creams, multifunctional sunscreens, biphasic formulations and sprayable products. Their suitability depends on technical feasibility and market-specific regulations.
European manufacturers can collaborate with US beauty brands on product development and manufacturing projects. However, sunscreens intended for the United States must meet applicable FDA requirements, and manufacturing and regulatory responsibilities must be clearly established.
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