Case Study: Development of Reef-Safe, Waterproof, Mineral Sunscreen
Introduction
With growing awareness of environmental and skin health concerns, One of our clients wanted to develop a reef-safe, waterproof, mineral sunscreen that combines high-performance UV protection with eco-conscious formulation. The project aimed to create two variants: a tinted sunscreen matching industry benchmarks and a non-tinted version, both adhering to strict criteria for safety, efficacy, and sustainability.
Key Objectives
- SPF 50 with Broad-Spectrum Protection: Shield against UVA/UVB rays using mineral blockers.
- Reef-Safe Formulation: Exclude oxybenzone, parabens, PABA, and fragrances to protect marine ecosystems.
- Dual Variants:
- Tinted Version: Pigment matching benchmark cosmetics.
- Non-Tinted Version: Clear, non-migrating formula.
- User-Centric Features: Non-greasy texture, hypo-allergenic, waterproof, and long-lasting adherence.
Methodology
Formulation Design
The approved formulations prioritized zinc oxide as the primary mineral UV blocker, for reef safety and broad-spectrum protection. Key innovations included:
- Tinted Variant: Incorporation of Red IO2 and Yellow IO2 pigments to achieve a natural skin-matching tone.
- Base Ingredients:
- Coconut Oil (in one variant) and Sunflower Oil for moisturizing benefits.
- A 3rd gen emulsifier and stabilizers to prevent migration and greasiness.
- Vit-E (Tocopheryl Acetate) for antioxidant protection.
Key Components
| Phase | Ingredients (INCI Names) | Function |
|---|---|---|
| A | DM Water, Sodium Gluconate, Glycerine | Hydration and pH balance |
| B | Caprylic/Capric Triglyceride, Coccus Nucifera (Coconut) Oil, Helianthus Annuus (Sunflower) Seed Oil | Moisturizing base |
| C | Zinc Oxide | Mineral UV blocker |
Results & Performance
- SPF 50 & Broad-Spectrum Protection: Achieved through optimized zinc oxide dispersion.
- Reef-Safe Compliance: Free from oxybenzone, parabens, and synthetic fragrances.
- Non-Migrating & Waterproof: Formulation ensured the formula adhered to skin without transferring.
- Hypo-Allergenic: Tested for sensitive skin with no adverse reactions reported.
- Aesthetic Appeal: Tinted variant matched benchmark cosmetics, offering a natural finish.
Challenges & Solutions
- Challenge: Balancing non-greasy texture with mineral sunscreen thickness.
Solution: Use of 3rd gen emulsifier to create a lightweight, spreadable emulsion. - Challenge: Preventing pigment settling in the tinted variant.
Solution: Stabilized pigments with Magnesium Stearate and optimized mixing protocols.
Conclusion
Researpa successfully delivered sunscreen that meets rigorous environmental and performance standards. The product stands out for its:
- Eco-Conscious Design: Protects coral reefs and marine life.
- Skin-Friendly Attributes: Ideal for sensitive skin and active lifestyles.
- Market Readiness: Dual variants cater to diverse consumer preferences.
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