The Complexities of Manufacturing Broad-Spectrum Sunscreens

Sunscreen is arguably the most difficult cosmetic product to manufacture correctly. It blurs the line between a daily cosmetic and an OTC therapeutic product. Consumers demand high SPF and PA ratings, but they reject products that leave a white cast, feel greasy, or pill under makeup.

The primary challenge lies in the dispersion of UV filters. Physical filters like Titanium Dioxide and Zinc Oxide tend to agglomerate (clump together) within the emulsion. If not properly dispersed using advanced high-shear homogenizers and precise milling equipment, the consumer will experience a chalky white cast and uneven UV protection.

Chemical filters face their own challenges, primarily photostability. Formulating sunscreens requires the addition of stabilizers and specific solvent phases to keep the chemical UV filters suspended and active when exposed to high-intensity sunlight.

At Biowil Formulation, we have specialized manufacturing vessels designed specifically for high-viscosity sun protection products. Our rigorous in-process controls ensure uniform dispersion, guaranteeing that the SPF rating on the label matches the performance on the skin.

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