Category: Blog Post

Overview of Global Cosmetic Regulatory Requirements

Expanding into multiple markets requires more than product innovation. It also requires a clear understanding of regional regulations and compliance pathways.

Why Cosmetic Compliance Matters

Regulatory compliance plays a critical role in:

• Consumer safety: Helping ensure products are safe for their intended use
• Market access: Meeting the legal requirements for sale in each region
• Brand protection: Reducing the risk of recalls, penalties or reputational damage
• Operational efficiency: Avoiding delays caused by compliance gaps

Each region sets its own expectations for:

• Ingredient restrictions and approvals
• Product safety assessments
• Labelling requirements
• Product notifications, listings or registrations

Without a structured compliance strategy, brands may face delayed launches, reformulation costs or restricted market entry.

Cosmetic Compliance Services in Australia

In Australia, different requirements can apply depending on the product, its ingredients and the claims being made. AICIS regulates the introduction of industrial chemicals, including chemicals used in many cosmetic products, while other requirements apply to areas such as product labelling and therapeutic goods.

AICIS and Ingredient Notifications

The Australian Industrial Chemicals Introduction Scheme regulates the introduction of industrial chemicals, including many ingredients used in cosmetic products, into the Australian market.

Key compliance requirements may include:

• Checking whether relevant chemical introductions are listed on the AICIS Inventory
• Determining the appropriate introduction category, where required
• Submitting required notifications or reports
• Maintaining the required records and supporting documentation

Australian Compliance Checklist

• Check the AICIS status of each ingredient
• Determine the appropriate introduction category
• Completing applicable reporting and annual declaration requirements
• Retain safety data and compliance documentation
• Review product labelling against applicable Australian requirements

Typical Australian Compliance Timelines

Timing will depend on the product, the regulatory pathway and the information and documentation available.

Areas to Check in Australia

• Ingredient introduction requirements
• Product classification
• Ingredient labelling
• Claims that may affect how the product is regulated
• Required records and documentation

Cosmetic Compliance Services in the European Union

The European Union has one of the most comprehensive cosmetic regulatory frameworks, requiring detailed safety assessments, product documentation and mandatory notification before market entry.

EU Cosmetic Regulation

Cosmetic products sold within the European Economic Area must comply with Regulation (EC) No. 1223/2009.

Core requirements include:

• A Product Information File
• A Cosmetic Product Safety Report
• An appointed Responsible Person based in the European Union
• Notification through the Cosmetic Products Notification Portal before the product is placed on the market
• Compliance with applicable restricted and prohibited ingredient requirements

European Union Compliance Checklist

• Review the full ingredient list against applicable annexes and restrictions
• Complete the safety assessment and Cosmetic Product Safety Report
• Compile and maintain the Product Information File
• Review labelling, including INCI names, claims, warnings and required translations
• Complete the Cosmetic Products Notification Portal submission

Cosmetic Compliance Services in the United States

In the United States, cosmetics are regulated by the Food and Drug Administration, with increased emphasis on safety substantiation, facility registration and product listing.

FDA Requirements and MoCRA

Cosmetics in the United States are regulated under the Federal Food, Drug, and Cosmetic Act, with additional obligations introduced through the Modernization of Cosmetics Regulation Act.

Key requirements may include:

• Ensuring product safety and compliant labelling
• Completing facility registration and product listing where applicable
• Meeting applicable adverse event reporting requirements
• Reviewing ingredient and colour additive compliance

United States Compliance Checklist

• Review ingredients, including applicable colour additive requirements
• Prepare and retain safety substantiation documentation
• Complete facility registration where required
• Complete product listing submissions where required
• Review warnings, directions and marketing claims

Comparing Cosmetic Compliance Across AU, EU and US Markets

Although all three markets focus on consumer safety, each region has a different compliance pathway.

Brands planning a multi-market launch should review all target markets early. This helps identify ingredient, claims and documentation conflicts before the product reaches final formulation or artwork.

How Delta Supports Cosmetic Regulatory Compliance

Regulatory requirements need to be considered alongside formulation, testing and manufacturing, particularly when a product is intended for more than one market.

End-to-End Compliance Support

At Delta, regulatory considerations form part of the wider product development and manufacturing process. This can include reviewing requirements that may affect:

• Ingredient selection
• Formulation development
• Product testing
• Labelling and artwork
• Manufacturing requirements
• The intended market for the finished product

Testing and Regulatory Requirements

Depending on the product and its intended market, testing requirements may need to be considered as part of the wider regulatory pathway. This may include:

• Stability testing
• Bacterial, Yeast and Mould testing
• Preservative efficacy testing
• Packaging compatibility testing
• Other product-specific testing where required

Practical Benefits for Brands

Working with an experienced compliance and manufacturing partner can help brands:

• Reduce time to market through more structured compliance workflows
• Minimise regulatory risk through early review and guidance
• Avoid costly reformulations caused by late-stage compliance issues
• Prepare products for expansion across multiple markets
• Align formulation, testing, labelling and manufacturing decisions

Build Compliance Into Product Development Early

Cosmetic regulatory compliance should not be treated as the final stage before launch. Ingredient choices, claims, testing, packaging and labelling can all create regulatory implications throughout the product development process.

By considering compliance early, brands can make more informed decisions, reduce avoidable delays and build products that are better prepared for their intended markets.

Delta helps cosmetic and personal care brands connect formulation, testing, compliance and manufacturing, creating a clearer pathway from concept through to commercial production.

A cosmetic formulation lab is where product ideas are transformed into stable, effective and manufacturable formulations. For cosmetic and skincare brands, the quality of formulation work can directly influence product performance, shelf life, compliance and manufacturing success.

At Delta, formulation is not treated as a standalone step. It is the foundation of a broader, compliance-first development process that supports products from concept through to commercial production.

For founders and product developers in the early stages of creation, working with an experienced cosmetic formulation lab in Australia can reduce complexity, improve speed to market and help prevent costly issues later in development.

What Is a Cosmetic Formulation Lab?

A cosmetic formulation lab is a specialised environment where cosmetic and personal care products are researched, designed, tested and refined before manufacturing.

This is where formulation science, product strategy and market goals come together. In practical terms, a formulation lab helps answer some of the most important early-stage product questions:

• Which ingredients will deliver the desired benefit?
• Will the formula remain stable over time?
• Can the product be manufactured consistently at scale?
• Does the formulation align with regulatory requirements?

For brands asking, “What does a cosmetic formulation lab do?”, the answer is simple: it helps turn a product idea into a viable formula that is ready for testing, scale-up and commercial production.

Why Formulation Matters to Product Success

Formulation is one of the most important stages in the product development lifecycle.

A well-formulated product is more likely to:

• Perform as intended
• Maintain consistency across batches
• Remain stable throughout its shelf life
• Meet consumer expectations for texture, appearance and usability
• Support regulatory and compliance requirements

A poorly developed formulation can create problems that appear much later, including instability, packaging compatibility issues, failed testing, reformulation delays or manufacturing inefficiencies.

That is why the work completed in a skincare formulation lab or cosmetic R&D environment can have such a strong influence on eventual manufacturing outcomes.

Inside the Delta Formulation Process

At Delta, formulation is a structured and collaborative process designed to create products that are innovative, compliant and ready for the realities of manufacturing.

Rather than focusing only on prototype creation, Delta’s formulation approach considers product performance, testing requirements, ingredient suitability and scale-up readiness from the beginning.

Step 1: Understanding the Product Brief

Every successful formulation begins with a clear understanding of the product vision.

This early stage typically includes:

• Product type and format
• Performance goals and intended claims
• Texture and sensory targets
• Ingredient preferences or exclusions
• Packaging considerations
• Intended market and compliance requirements

Starting with a detailed brief helps ensure the formula is developed with both commercial and technical success in mind.

Step 2: Ingredient Research and Selection

Ingredient selection is one of the most critical parts of cosmetic development. The right combination of ingredients affects not only product performance, but also stability, safety, cost and manufacturability.

At this stage, formulation teams consider:

• Functional ingredients and actives
• Emulsifiers, thickeners and stabilisers
• Preservative systems
• Sensory modifiers
• Compatibility between raw materials
• Regional regulatory considerations

This is where a strong cosmetic formulation services partner adds real value. Ingredient choices are not made in isolation. They are assessed in the context of the complete formulation, the intended user experience and future testing requirements.

Step 3: Prototype Development

Once the initial ingredient strategy is defined, the lab begins prototype development.

This phase involves creating early versions of the formula and refining them through controlled testing and review. Depending on the product category, this may include:

• Adjusting texture and viscosity
• Improving spreadability or absorption
• Balancing fragrance and sensory profile
• Fine-tuning emulsion stability
• Optimising appearance and consistency

Prototype development is rarely a one-step process. It usually involves several iterations, each informed by technical observations and client feedback.

At Delta, prototype work is approached with the end goal in mind: a product that not only performs well in the lab, but can also move successfully through testing and into production.

Testing, Stability and Compliance

A formulation is only as strong as its ability to pass testing, remain stable and meet market requirements.

A cosmetic product may look promising at prototype stage, but its real-world performance depends on how it responds to time, temperature, packaging and microbial challenge. This is why formulation and validation need to work together.

Performance and Shelf-Life Testing

Formulations developed in a cosmetic lab should be supported by testing that confirms product quality, safety and durability.

This can include:

• Stability testing: Assesses product performance over time under different storage conditions.
• Packaging compatibility testing: Evaluates how the formulation interacts with its intended packaging.
• Microbiological testing: Helps confirm product safety and preservative performance.
• Physical and performance testing: Monitors characteristics such as pH, viscosity, colour, odour and texture.

Testing helps identify whether a formula is ready to move forward or requires further refinement.

For brands, this reduces the risk of:

• Shelf-life failures
• Packaging incompatibility
• Texture breakdown
• Preservative weakness
• Late-stage reformulation

Why Compliance Matters Early

Compliance should not be treated as a final checkpoint. It should be considered throughout formulation development.

A compliance-first approach can help address:

• Ingredient restrictions in target markets
• Labelling implications
• Safety documentation requirements
• Market-specific expectations for cosmetics and skincare

This is especially important for brands planning to grow across regions or prepare for manufacturing without delays. A formula that performs well but creates regulatory complications can significantly slow launch timelines.

At Delta, formulation is supported by a broader understanding of testing and compliance, helping brands build stronger products from the beginning.

From Lab to Manufacturing Scale

The transition from formulation lab to production is where many products succeed or fail. A formula must be more than innovative; it must also be scalable.

A common challenge in product development is that a formula performs well in a small laboratory batch but behaves differently during larger-scale manufacturing. Differences in mixing, heating, order of addition and equipment can all affect the final result.

Transitioning from R&D to Production

Formulation should always be developed with manufacturing in mind. A scale-ready process often includes:

1. Lab-scale development: Initial formula creation and refinement.
2. Testing and validation: Assessment of stability, compatibility and safety.
3. Pilot-scale review: Evaluation of how the formula performs under production-like conditions.
4. Process adjustment: Refinement of the method, order of addition and processing parameters.
5. Manufacturing readiness: Final preparation for repeatable, commercial-scale production.

By linking R&D with production thinking early, Delta helps reduce the risk of delays, inconsistencies and costly reformulation when products move beyond the bench.

This connection between formulation and manufacturing success is one of the key advantages of working with an experienced cosmetic formulation lab in Australia.

How Delta Supports Cosmetic Formulation

Delta supports cosmetic and skincare brands through formulation development, testing, compliance planning, scale-up and commercial manufacturing.

Bringing these capabilities together helps create products that are not only aligned with the original concept, but also technically robust, commercially practical and ready for production.

Delta’s formulation support can include:

• Product brief development
• Ingredient research and selection
• Prototype development and refinement
• Stability and compatibility planning
• Microbiological and performance testing pathways
• Compliance considerations
• Pilot-scale review
• Manufacturing scale-up
• Commercial production

Strong Products Begin with the Right Formulation Partner

Successful cosmetic product development requires more than creating an appealing laboratory sample. The formula must also remain stable, meet relevant requirements, work with its packaging and perform consistently when manufactured at scale.

By considering formulation, testing, compliance and production together, brands can build stronger foundations and reduce avoidable issues later in development.

Delta helps cosmetic and skincare brands move from early product ideas through to tested, scalable and commercially manufactured formulations.

Launching an SPF range requires more planning than a standard skincare launch. Brands need to consider sunscreen regulation, SPF testing, claims, formulation complexity, packaging compatibility, manufacturing timelines and commercial positioning before moving from concept to market.

For beauty and skincare brands, SPF can be a powerful range extension. Daily sun protection is now a core part of modern skincare, and consumers are looking for sunscreen products that feel elegant, work under makeup, suit different skin types and align with their values.

But sunscreen is also one of the most technically demanding categories to launch. A successful SPF product needs to be more than appealing on shelf. It needs to perform reliably, meet relevant Australian requirements, remain stable in its packaging, support its claims and be manufacturable at commercial scale.

This guide explains what brands should know before launching an SPF range, including compliance, formulation, testing, manufacturing, branding and launch readiness considerations.

What Do Brands Need Before Launching Sunscreen?

Before launching sunscreen, brands need a clear product strategy, regulatory pathway, testing plan, packaging direction, manufacturing partner and commercial launch timeline.

An SPF launch should begin with a structured brief. This helps the formulation and manufacturing team understand what the brand wants to create and whether the concept is technically, commercially and regulatory feasible.

Before development begins, brands should define:

• The type of SPF product they want to launch
• The target SPF level
• The intended market and sales channels
• The desired claims and positioning
• The preferred formula type and skin feel
• The packaging format
• The target cost of goods
• The expected order volumes
• The launch date and retailer deadlines
• The level of regulatory and manufacturing support required

Brands that enter SPF development without a clear brief often lose time later. Claims may need to be revised, packaging may need to change, testing may take longer than expected, or the formula may need to be adjusted to achieve the desired performance.

How Are SPF Products Regulated in Australia?

In Australia, many sunscreen products are regulated as therapeutic goods when their primary purpose is UV protection.

This is one of the most important things brands need to understand before launching an SPF range. Sunscreen products are not always treated the same way as standard cosmetics. Depending on the product type, SPF level, intended purpose and claims, the product may need to meet therapeutic goods requirements before it can be supplied in Australia.

For brands, sunscreen compliance can influence:

• Which sunscreen actives can be used
• How the product is tested
• What claims can be made
• What must appear on the label
• Whether the product requires ARTG inclusion
• What manufacturing standards apply
• What documentation needs to be retained

Regulatory planning should happen early. A product concept that sounds simple from a marketing perspective may carry specific requirements once SPF, broad-spectrum or water-resistance claims are introduced.

Cosmetic SPF vs Therapeutic Sunscreen: What Is the Difference?

The difference between a cosmetic SPF product and a therapeutic sunscreen depends on the product’s purpose, claims and regulatory classification.

Some products may sit closer to cosmetic skincare, while others are clearly developed and marketed as sun protection products. Brands should confirm the likely pathway before investing heavily in formulation, packaging or campaign language.

This distinction matters because the product pathway affects the entire launch process. It can influence formulation decisions, testing requirements, documentation, label content, manufacturing controls and time to market.

What Testing Is Needed Before Selling Sunscreen?

SPF products need testing to support performance, quality, stability and claims before launch.

Testing should be planned into the project timeline from the beginning. It is not simply a final approval step after the product has been formulated. If testing identifies an issue, the formula, packaging or claims may need to be adjusted.

Depending on the product and claims, testing may include:

• SPF testing
• Broad-spectrum testing
• Water-resistance testing
• Stability testing
• Microbiological testing
• Preservative efficacy testing
• Packaging compatibility testing
• Claims substantiation

For SPF brands, testing timelines can be one of the biggest launch risks. A product that does not achieve its target SPF, broad-spectrum performance or stability requirements may need reformulation and retesting. This can affect retailer commitments, campaign timing and cash flow.

Why SPF Formulation Is More Complex Than Standard Skincare

SPF formulation is complex because the product must deliver measurable UV protection while still feeling pleasant on the skin.

Consumers expect modern sunscreens to be lightweight, non-greasy, easy to apply, compatible with makeup and suitable for daily use. At the same time, the formula needs to achieve its target SPF, remain stable, work with the selected packaging and be suitable for commercial manufacturing.

SPF formulation decisions may affect:

• SPF performance
• Broad-spectrum protection
• White cast
• Texture and spreadability
• Greasy or tacky after-feel
• Pilling under skincare or makeup
• Water resistance
• Stability over time
• Packaging compatibility
• Manufacturing efficiency

This is why SPF should not be treated as a simple skincare add-on. Adding sunscreen actives to an existing moisturiser concept may not create a product that performs, feels good and meets the required pathway. SPF products need to be designed as SPF products from the start.

How Can Brands Differentiate an SPF Range?

Brands can differentiate an SPF range through audience, texture, format, skin benefits, claims strategy, packaging and brand positioning.

The SPF category is competitive, so brands should avoid launching a generic sunscreen without a clear reason to exist. Differentiation should be built into the product strategy before formulation begins.

However, differentiation must still be realistic. Claims need to be supportable, the formula needs to be stable, packaging needs to work, and the product needs to be commercially viable at the intended price point.

What Claims Should SPF Brands Be Careful With?

SPF brands should be careful with any claim that relates to protection, duration, water resistance, skin safety, ingredient absence or therapeutic performance.

Claims are a common source of launch risk. Language that sounds appealing from a marketing perspective may create compliance concerns if it is inaccurate, unsupported or inconsistent with the product’s evidence.

Brands should take care with claims such as:

• Waterproof
• All-day protection
• Once-daily application
• Blocks all UV rays
• Chemical-free
• Non-toxic
• Safe for all skin types
• Dermatologist approved
• Reef safe
• Suitable for babies or children

This does not mean brands cannot make strong claims. It means claims should be planned, reviewed and supported by appropriate evidence. Packaging, website copy, advertising, social media and retailer descriptions should all align with the approved claims strategy.

What Manufacturing Logistics Should Brands Plan For?

SPF manufacturing requires planning around ingredients, packaging, testing, batch size, lead times, quality checks and production documentation.

Manufacturing is often where launch timelines become real. A brand may have a strong concept and approved formula, but production still depends on raw material availability, packaging supply, batch scheduling, filling requirements and quality release processes.

Brands should plan for:

• Raw material lead times
• Packaging procurement
• Packaging compatibility testing
• Manufacturing batch size
• Filling format
• Quality control checks
• Batch documentation
• Retain samples
• Finished goods release
• Freight and warehouse timing

For startup brands, it is important to understand minimum order quantities and cash flow implications. For established brands, the focus may be on scalability, retailer deadlines, repeat production and maintaining consistency across batches.

How Long Does an SPF Product Launch Take?

An SPF product launch usually takes longer than a standard skincare launch because it involves formulation, testing, compliance review, packaging and manufacturing stages.

Exact timing depends on the product complexity, regulatory pathway, claims, testing requirements and packaging. A simple product may move faster, while a highly customised SPF with specific sensory, water-resistance, tint, mineral-only or multi-market requirements may take longer.

The safest approach is to build contingency into the timeline. SPF launch delays often come from reformulation, failed testing, packaging changes, unsupported claims or late artwork revisions.

SPF Range Launch Checklist

A strong SPF launch plan should cover compliance, formulation, manufacturing, packaging and commercial readiness before production begins.

Before launching an SPF range, brands should ask:

• Have we confirmed the likely regulatory pathway?
• Are our SPF, broad-spectrum and water-resistance claims realistic?
• Have we selected a manufacturer with SPF experience?
• Is our formulation brief technically achievable?
• Have we allowed time for testing and possible reformulation?
• Has packaging been tested for compatibility?
• Are our claims supported by appropriate evidence?
• Has artwork been reviewed before printing?
• Have we planned raw material and packaging lead times?
• Do we understand minimum order quantities and production costs?
• Have we planned future production runs and replenishment?
• Do we have a clear launch position in the SPF category?

This checklist helps brands avoid treating SPF as a standard skincare launch. The earlier these questions are answered, the smoother the development and production process is likely to be.

Common Mistakes Brands Make When Launching SPF

The most common SPF launch mistakes happen when brands underestimate compliance, testing, formulation complexity or manufacturing timelines.

SPF can be commercially attractive, but it is not a category to rush. Mistakes made early in the process can lead to delays, additional costs, reformulation or claims changes close to launch.

Common mistakes include:

• Finalising packaging before confirming the formula
• Making claims before confirming the evidence required
• Assuming SPF is the same as standard skincare
• Underestimating testing timelines
• Choosing a manufacturer without SPF experience
• Ignoring packaging compatibility
• Setting unrealistic launch dates
• Trying to achieve too many product benefits in one formula
• Not planning for scale-up
• Leaving regulatory review too late

These issues are avoidable with the right development plan. A clear brief, experienced manufacturing partner and realistic timeline can help brands reduce risk before significant investment is committed.

How Delta Supports SPF Range Development

Delta supports beauty, skincare and sun care brands with SPF formulation, manufacturing and launch planning built around technical quality and commercial readiness.

Launching an SPF range requires decisions across formulation, compliance, testing, packaging, production and market positioning. Delta works with brands to help turn SPF concepts into manufacturable, market-ready products with the right planning in place from the beginning.

For SPF projects, Delta can support:

• Product concept development
• Custom SPF formulation
• Texture and sensory refinement
• Testing pathway planning
• Packaging compatibility considerations
• Manufacturing scale-up
• Quality-focused production
• Commercial production planning

With SPF, experience matters. The right manufacturing partner can help brands understand what is possible, what needs to be tested and where the biggest launch risks may appear.

FAQs About Launching an SPF Range

What Do Brands Need Before Launching Sunscreen?

Brands need a clear product concept, regulatory pathway, claims strategy, formulation brief, testing plan, packaging direction, manufacturing partner and commercial launch timeline. SPF products usually require more planning than standard skincare products.

How Are SPF Products Regulated in Australia?

In Australia, many sunscreen products are regulated as therapeutic goods when their primary purpose is UV protection. Depending on the product type and claims, brands may need to consider ARTG inclusion, permitted ingredients, sunscreen testing, labelling requirements and manufacturing standards.

What Testing Is Needed Before Selling Sunscreen?

Testing may include SPF testing, broad-spectrum testing, water-resistance testing, stability testing, microbiological testing, preservative efficacy testing, packaging compatibility testing and claims substantiation. The required testing depends on the product and claims.

How Do You Create a Sunscreen Brand?

Creating a sunscreen brand starts with a clear market position, target audience and product strategy. Brands then need to develop a compliant and commercially viable SPF formula, complete relevant testing, finalise packaging and manufacture the product with a suitable production partner.

Can an Existing Skincare Brand Add SPF to Its Range?

Yes, an existing skincare brand can add SPF to its range, but SPF development should be treated as a specialist project. The brand needs to consider sunscreen regulation, testing, claims, formulation complexity, packaging compatibility and manufacturing requirements.

Why Does SPF Development Take Longer Than Standard Skincare?

SPF development often takes longer because the product must achieve measurable sun protection performance, meet relevant regulatory and labelling expectations, remain stable and support claims with appropriate evidence. Reformulation or retesting can also add time.

What Should Brands Ask an SPF Manufacturer?

Brands should ask whether the manufacturer has SPF formulation experience, understands sunscreen compliance, can support testing pathways, can scale production, has suitable quality systems and can help identify technical risks before launch.

Launch Your SPF Range With the Right Foundations

Launching an SPF range can be a strong growth move for beauty and skincare brands, but it requires careful planning. The brands that succeed are the ones that treat SPF as a regulated, performance-led category from the beginning.

Before launch, brands should understand the regulatory pathway, formulate with testing in mind, choose packaging carefully, plan realistic timelines and work with a manufacturer that understands SPF development and production.

For skincare, sun care and health brands, entering a regulated category can be a valuable growth opportunity. Products such as therapeutic sunscreens can build consumer trust and create strong commercial differentiation, but they also come with higher expectations around compliance, quality systems and manufacturing controls.

This guide explains what brands should expect when working with a TGA-listed product manufacturer, including the difference between cosmetic and therapeutic products, what GMP manufacturing means, what documentation may be involved, and the questions to ask before choosing a manufacturing partner.

What Is a TGA-Listed Product?

A TGA-listed product is a therapeutic good that has been included in the Australian Register of Therapeutic Goods, commonly referred to as the ARTG.

In Australia, some products that sit close to skincare, sun care or personal care may be regulated as therapeutic goods depending on their ingredients, intended use, presentation and claims. For brands, this means the product development process may involve more than formulation and packaging. It may also require evidence, documentation, quality systems and appropriate manufacturing controls.

TGA-listed products are often identified by an AUST L number on the label. This number indicates that the product has been included in the ARTG as a listed therapeutic good. However, brands should not treat this as a simple labelling step. The regulatory pathway needs to be considered early, before claims, packaging and launch timelines are finalised.

Sunscreens as Therapeutic Goods in Australia

Many sunscreens in Australia are regulated as therapeutic goods because their primary purpose is to protect the skin from ultraviolet radiation.

This is especially relevant for brands developing SPF products such as facial sunscreens, body sunscreens, sport sunscreens, water-resistant sunscreens or high-SPF sun protection products. Depending on the product and its claims, sunscreen manufacturing may need to meet therapeutic goods requirements rather than standard cosmetic manufacturing expectations.

For brands, this can affect:

• Ingredient selection
• Permitted sunscreen actives
• SPF and broad-spectrum testing
• Water-resistance claims
• Artwork and labelling
• Manufacturing documentation
• Batch release requirements
• Product evidence and record keeping

Because sunscreen is a performance-led product, brands should work with a manufacturer that understands both formulation science and the compliance expectations surrounding therapeutic sunscreen production.

Differences Between Cosmetic and Therapeutic Claims

The difference between a cosmetic product and a therapeutic product often comes down to the product’s intended purpose and the claims made about it.

A cosmetic product may focus on appearance, cleansing, moisturising, fragrance or general skin feel. A therapeutic product, by contrast, may be presented as preventing, treating or protecting against a health-related condition or risk. In the case of sunscreens, UV protection and sunburn prevention can place products into a therapeutic framework.

Brands should be careful not to build their product concept around marketing claims before understanding whether those claims are suitable for the intended regulatory pathway.

What to Expect From a TGA-Compliant Manufacturer

A TGA-compliant manufacturer should provide structured quality systems, controlled production processes, clear documentation and experience working within regulated product categories.

For brands, the manufacturer is not just a production supplier. In regulated categories, the manufacturer is a critical partner in product quality, process control and evidence generation. The right partner can help brands understand what needs to be planned before production begins and what records must be maintained throughout the product lifecycle.

GMP Manufacturing Standards

GMP, or Good Manufacturing Practice, refers to the systems and controls used to ensure products are consistently manufactured to the required quality standard.

In the context of TGA-listed sunscreen manufacturing, GMP expectations can cover personnel, premises, equipment, documentation, production, quality control, outsourced activities, complaints, recall processes, validation and reference samples.

For brands, this means the manufacturing process is expected to be controlled and repeatable. Ingredients should be checked, equipment should be suitable, procedures should be documented, batches should be traceable and finished products should be assessed before release.

Documentation and Quality Systems

Documentation is one of the biggest differences between standard cosmetic development and TGA-listed product manufacturing.

Brands should expect more formal records at each stage of development, manufacturing and release. Documentation may vary depending on the product and pathway, but it commonly supports the product’s formulation, quality, testing, manufacturing process and finished specifications.

Common documentation may include:

• Approved formula records
• Raw material specifications
• Finished product specifications
• Manufacturing instructions
• Batch manufacturing records
• Quality control records
• SPF and performance testing reports
• Stability testing reports
• Microbiological testing records
• Packaging specifications
• Artwork and label review records
• Release documentation
• Retain sample records

Clear documentation helps protect both the brand and the manufacturer. It provides a record of what was made, how it was made, what was tested and whether the product met the required specifications.

Batch Traceability and Quality Assurance

Batch traceability allows a manufacturer to track the materials, process steps, testing and release status of each production batch.

This is particularly important for TGA-listed products because quality issues must be investigated in a structured way. If a question arises about a finished product, the manufacturer should be able to trace the batch back through raw materials, processing records, equipment, operators, testing results and packaging components.

Quality assurance may include checks such as:

• Raw material approval
• Supplier documentation review
• In-process checks
• Finished product testing
• Batch record review
• Deviation management
• Release approval
• Retain sample storage

For brands, this level of traceability gives greater confidence that the product can be manufactured consistently across future production runs.

The Role of Testing in TGA-Listed Products

Testing is central to TGA-listed product manufacturing because claims, quality and product performance need to be supported by appropriate evidence.

Testing should not be treated as a final administrative step. For regulated products, the testing pathway should be considered during formulation development, packaging selection and launch planning. If testing identifies an issue, the formula, packaging, claim or manufacturing process may need to be adjusted.

SPF Testing Requirements

For therapeutic sunscreens, SPF testing supports the sun protection claim made on the product label.

SPF testing is a critical part of sunscreen development because the claimed SPF level must be supported by suitable evidence. Depending on the product, testing may also be required to support broad-spectrum claims, water resistance claims or other performance-related statements.

Brands should allow enough time for testing, review and potential reformulation. If a product does not achieve the target SPF or claim profile, additional development work may be required before the product can proceed.

Stability and Microbiological Testing

Stability and microbiological testing help confirm that the product remains suitable, consistent and safe throughout its intended shelf life.

Stability testing may assess changes in appearance, odour, colour, viscosity, pH, separation, packaging compatibility and product performance under defined conditions. Microbiological testing helps assess product quality and preservative system performance.

For SPF products, stability is especially important because changes in the formulation can affect consumer experience, product quality and confidence in performance. Packaging should also be assessed because the wrong pack can create issues with leakage, dispensing, compatibility or product protection.

Questions Brands Should Ask Potential Manufacturers

Choosing a manufacturer for TGA-listed products should involve more than comparing pricing and minimum order quantities.

Brands should assess whether the manufacturer has the right experience, quality systems, technical capability and regulatory awareness to support the product from development through to production.

Experience With Sunscreen Formulation

SPF formulation is highly specialised, so brands should ask whether the manufacturer has experience developing and scaling sunscreen products.

Useful questions include:

• Have you developed therapeutic sunscreen products before?
• Do you support custom SPF formulation?
• Can you advise on UV filter strategy and formulation feasibility?
• Can you help identify risks before testing begins?
• Do you understand SPF, broad-spectrum and water-resistance claim requirements?

Regulatory Support Capabilities

A manufacturer should be clear about what regulatory support they can provide and where a separate regulatory consultant or sponsor responsibility may be required.

Brands should ask:

• What documentation can you provide to support the product record?
• Can you support artwork and label review from a manufacturing perspective?
• Can you guide testing requirements and timing?
• Do you have experience working with TGA-listed products?
• What information does the brand need to provide before production?

Production Scalability and Lead Times

The right manufacturer should be able to support both the first production run and future scale-up requirements.

Brands should ask:

• What batch sizes can you support?
• What are typical production lead times?
• How are raw material lead times managed?
• Can the formula be scaled without compromising quality?
• What quality checks happen before batch release?

Manufacturer Selection Checklist

Before choosing a TGA-listed product manufacturer, brands should confirm that the partner can support the technical, quality and documentation needs of the product.

Common Challenges in TGA-Listed Product Manufacturing

The most common challenges in TGA-listed product manufacturing come from underestimating the time, evidence and documentation required.

Brands often encounter issues when they finalise claims too early, choose packaging before compatibility testing, underestimate testing timelines or assume a sunscreen can be treated like a standard cosmetic moisturiser.

Common challenges include:

• Unclear regulatory pathway
• Unsupported marketing claims
• SPF results below the target claim
• Stability failures
• Packaging compatibility issues
• Incomplete documentation
• Raw material supply delays
• Scale-up changes between lab and production
• Artwork revisions close to launch
• Unrealistic production timelines

These challenges can usually be managed with early planning. Brands should involve their manufacturer before finalising claims, artwork, packaging or retailer launch dates.

Why Experience Matters in SPF Manufacturing

Experience matters because SPF manufacturing requires a combination of formulation skill, process control, testing awareness and quality discipline.

Sunscreen products need to perform reliably while still meeting consumer expectations for texture, finish, packaging and usability. This makes formulation and manufacturing more complex than many standard skincare products.

An experienced SPF manufacturer can help brands understand what is technically achievable, what needs to be tested, what documentation may be required and where development risks may appear. This can help reduce avoidable delays and support a more confident path to market.

How Delta Supports TGA-Listed Product Manufacturing

Delta supports brands developing regulated sunscreen and therapeutic-style products with formulation, manufacturing and quality-focused production capability.

For brands entering TGA-listed product categories, Delta provides a structured manufacturing partnership built around technical knowledge, quality systems and commercial production experience. This includes support across product development, formulation feasibility, testing pathways, documentation, scale-up and production planning.

Delta’s role is to help brands move through the manufacturing process with greater clarity, from early product development through to finished goods production. For SPF and regulated topical products, this means considering performance, stability, packaging, documentation and manufacturing controls from the beginning.

FAQs About TGA-Listed Manufacturing

What Is a TGA-Listed Sunscreen?

A TGA-listed sunscreen is a sunscreen product that has been included in the Australian Register of Therapeutic Goods as a listed therapeutic good. These products commonly carry an AUST L number and must meet applicable requirements for ingredients, claims, evidence, labelling and manufacturing.

What Does GMP Manufacturing Mean?

GMP stands for Good Manufacturing Practice. It refers to the systems, processes and controls used to ensure products are manufactured consistently and meet defined quality standards. For therapeutic sunscreens, GMP can apply to areas such as documentation, production, quality control, premises, equipment, complaints and batch release.

How Do Manufacturers Support TGA Compliance?

Manufacturers can support TGA compliance by producing products under appropriate quality systems, maintaining batch documentation, following controlled manufacturing processes, supporting testing requirements and helping brands understand manufacturing-related documentation. Regulatory responsibilities can vary, so brands should confirm roles clearly at the start of the project.

What Documentation Is Needed for TGA-Listed Products?

Documentation may include approved formulas, specifications, raw material records, batch manufacturing records, quality control results, testing reports, packaging specifications, artwork records, release documentation and retain sample records. The exact requirements depend on the product and regulatory pathway.

Is TGA-Listed Sunscreen Manufacturing Different From Cosmetic Manufacturing?

Yes. TGA-listed sunscreen manufacturing generally involves higher expectations around evidence, documentation, quality systems and manufacturing controls than standard cosmetic manufacturing. Brands should work with a manufacturer that understands the requirements of regulated sunscreen production.

When Should a Brand Speak to a Manufacturer?

Brands should speak to a manufacturer as early as possible, ideally before finalising the formula brief, claims, packaging or launch date. Early manufacturing input can help identify technical, testing and documentation requirements before they become costly delays.

Work With the Right Manufacturer From the Start

Working with a manufacturer for TGA-listed products requires planning, structure and trust. The right partner should help brands understand what to expect across formulation, testing, documentation, quality control and production.

For sunscreen and regulated topical products, early decisions can have a major impact on compliance, performance and launch timing. Choosing an experienced manufacturing partner can help brands reduce uncertainty and move through the process with greater confidence.

Developing an SPF product requires more than choosing UV filters and creating a pleasant texture. Brands need to consider regulatory classification, formulation strategy, SPF and broad-spectrum testing, stability, packaging compatibility, manufacturing scale-up and launch timelines.

A typical SPF development process includes:

1. Defining the product concept and market positioning
2. Confirming the regulatory pathway
3. Building the sunscreen formulation strategy
4. Developing and refining prototypes
5. Conducting stability and compatibility testing
6. Completing SPF, broad-spectrum and claims testing
7. Finalising packaging and artwork
8. Scaling up to manufacturing
9. Completing quality checks and release requirements
10. Launching with compliant claims and supporting evidence

For Australian brands, working with an experienced SPF manufacturer can help reduce risk, improve development efficiency and ensure technical requirements are considered from the beginning.

What Is SPF Product Development?

SPF product development is the end-to-end process of creating a sunscreen or SPF-containing product that is formulated, tested, manufactured and prepared for market.

At a simple level, it involves turning a product idea into a finished sunscreen that consumers can buy and use. In practice, it is a highly technical process involving formulation science, regulatory planning, ingredient selection, performance testing, packaging decisions and commercial scale manufacturing.

An SPF product may be developed as a standalone sunscreen, a daily facial SPF, a tinted sunscreen, an SPF moisturiser, an after-sun adjacent range extension, or a specialist product for sport, family, sensitive skin or outdoor use. Each product type comes with different formulation and compliance considerations.

The most successful SPF projects start with a clear brief. A manufacturer or formulation partner needs to understand what the product is intended to do, who it is for, what claims the brand wants to make, the desired texture and finish, the target price point, packaging preferences and the expected launch timeline.

Step 1: Define the SPF Product Concept

The first stage is to clearly define what the sunscreen product should be and where it will sit in the market.

Before formulation begins, brands should clarify the product’s role in the range. Is it a daily facial sunscreen? A body SPF? A sport sunscreen? A mineral-only formula? A tinted SPF? A moisturiser with SPF? These decisions shape the formulation, testing requirements, packaging choices and commercial strategy.

A strong SPF brief should include:

• Product type and format
• Target SPF level
• Desired texture and finish
• Skin type or consumer segment
• Preferred active ingredient approach
• Claims the brand wants to make
• Packaging format
• Target cost of goods
• Expected order volumes
• Launch timing
• Retail or distribution channel

This stage is also where brands should assess whether their concept is technically realistic. For example, a high SPF, ultra-light, mineral-only, water-resistant, fragrance-free, low-cost product may be possible in some form, but it may require trade-offs across skin feel, whiteness, cost, packaging or development time.

The clearer the concept, the easier it is to develop a formula that balances brand vision with technical reality.

Step 2: Confirm the Regulatory Pathway

In Australia, many sunscreen products are regulated as therapeutic goods, which means compliance needs to be considered before formulation starts.

This is one of the most important steps in SPF product development. Sunscreens are not always treated like standard cosmetics, especially when their primary purpose is UV protection. Depending on the product type, claims, SPF level and intended use, the sunscreen may need to meet specific therapeutic goods requirements before it can be supplied in Australia.

Brands should consider:

• Whether the product is a primary or secondary sunscreen
• Whether it requires inclusion in the Australian Register of Therapeutic Goods
• Which active sunscreen ingredients are permitted
• What claims can and cannot be made
• What evidence is required to support performance claims
• What labelling requirements apply
• Whether the manufacturer has the right capabilities and quality systems

This is where early regulatory guidance is critical. A concept that sounds simple from a marketing perspective may carry specific compliance obligations once SPF claims are introduced.

For brands planning to sell in multiple markets, regulatory planning becomes even more important. Australia, the United States and the European Union do not treat sunscreen products in exactly the same way. A formula or claim strategy that works in one market may need adjustment for another.

Step 3: Build the Sunscreen Formulation Strategy

Sunscreen formulation is highly specialised because the formula must deliver both protection and a desirable user experience.

The formulation strategy determines how the product will achieve its SPF performance, texture, stability and sensory profile. It includes decisions around UV filters, emulsifier systems, preservatives, moisturising ingredients, film formers, thickeners, antioxidants, fragrance, colourants and supporting skin-benefit ingredients.

A custom SPF formulation may need to balance:

• UV protection
• Broad-spectrum performance
• Water resistance
• Skin feel
• Spreadability
• White cast
• Greasiness
• Pilling
• Eye sting
• Stability
• Packaging compatibility
• Cost
• Manufacturing efficiency

One of the biggest challenges in sunscreen formulation is that every ingredient can affect performance. The UV filters may determine the protection profile, but the emulsion structure, oil phase, film formation, viscosity and packaging can all influence how the product behaves.

This is why SPF products are rarely simple “add SPF to skincare” projects. A moisturiser with SPF still needs to be developed as an SPF product, not just a moisturiser with sunscreen actives added at the end.

Step 4: Choose the Right UV Filter Approach

The UV filter system is central to how a sunscreen performs, feels and is positioned.

UV filters are ingredients that help protect the skin from ultraviolet radiation. Sunscreen products may use chemical filters, mineral filters or a combination of both. Each approach has advantages and challenges.

The best UV filter strategy depends on the product goal. A lightweight daily facial SPF may need a different approach from a water-resistant body sunscreen or a mineral-only baby-positioned product.

Brands should avoid choosing filters based on marketing preference alone. The filter system needs to be considered alongside target SPF, skin feel, regulatory status, supply chain availability, manufacturing process and testing pathway.

Step 5: Develop and Refine Prototypes

Prototype development turns the concept and formulation strategy into sample products that can be evaluated and improved.

The first prototype is rarely the final formula. SPF product development usually requires several rounds of formulation adjustment to balance performance, aesthetics, stability and manufacturability.

During prototype refinement, the formulation team may assess:

• Texture and spreadability
• Absorption and finish
• White cast or transparency
• Pilling under skincare or makeup
• Fragrance profile
• Viscosity
• Water resistance potential
• Compatibility with packaging
• Early stability indicators
• Manufacturing practicality

Feedback at this stage should be structured. Rather than simply saying a sample feels “too heavy” or “not premium enough”, brands should describe the desired direction. For example: lighter after-feel, faster rub-in, less shine, more cushion, softer finish, lower tack, better makeup compatibility or less visible residue.

This helps the formulation team make targeted adjustments instead of guessing.

Step 6: Conduct Stability and Compatibility Testing

Stability testing helps confirm whether the formula remains safe, consistent and suitable over time.

For SPF products, stability is especially important because product performance depends on the formula remaining physically and chemically consistent. Changes in viscosity, separation, odour, colour, pH, microbial quality or packaging interaction can affect consumer experience and potentially compromise product quality.

Stability testing may assess the product under different conditions, such as elevated temperature, room temperature, light exposure or freeze-thaw cycles. Packaging compatibility testing assesses how the formula behaves in the intended pack.

Common issues found during SPF stability work include:

• Formula separation
• Viscosity drift
• Grittiness or crystallisation
• Colour or odour change
• Preservative system issues
• Packaging swelling, leakage or staining
• Pump or closure performance problems
• Changes in application feel

Packaging should not be finalised too late in the process. A formula may behave well in a lab jar but perform differently in a tube, pump, airless pack or spray format. Testing the formula in the intended packaging helps reduce the risk of launch issues.

Step 7: Complete SPF and Performance Testing

SPF testing verifies whether the product achieves the level of sun protection it intends to claim.

Testing is a critical milestone in sunscreen product development. Brands need evidence to support SPF, broad-spectrum, water resistance and other performance claims where relevant.

The testing pathway depends on the product type and claims, but may include:

• SPF testing
• Broad-spectrum testing
• Water resistance testing
• Stability testing
• Microbiological testing
• Preservative efficacy testing
• Compatibility testing
• Claims substantiation

SPF testing is not just a box to tick at the end. If a product does not achieve the intended SPF or claim profile, reformulation may be required, followed by further testing. This can add time and cost to the development process.

This is why experienced SPF formulators often build testing considerations into the formula from the start. Early technical decisions can influence the likelihood of achieving the desired SPF, skin feel and stability profile.

Step 8: Finalise Packaging and Artwork

Packaging and artwork need to support both product performance and regulatory compliance.

For SPF products, packaging is not only a branding decision. The packaging format can affect stability, usability, dosing, product protection and consumer experience. It also needs to accommodate the required labelling information.

Packaging decisions may include:

• Tube, pump, airless, bottle, jar or spray format
• Fill volume
• Closure system
• Barrier properties
• Dispensing behaviour
• Decoration method
• Label space
• Retail presentation
• Transport durability
• Compatibility with the formula

Artwork should be reviewed carefully before printing. SPF products may require specific information on pack, including SPF level, usage directions, active ingredients, warnings, storage instructions, AUST L details where relevant, and compliant claims language.

Brands should be particularly careful with marketing claims. Words such as “waterproof”, “all-day protection” or “chemical-free” can create compliance concerns. Claims should be accurate, supportable and aligned with applicable requirements.

Step 9: Scale Up to Manufacturing

Manufacturing scale-up ensures the product can be made consistently beyond the lab bench.

A formula that works in a small laboratory batch still needs to be translated into a commercial manufacturing process. This involves confirming mixing order, processing temperatures, equipment requirements, batch size, filling parameters, quality checks and production documentation.

Scale-up considerations may include:

• Ingredient sourcing and lead times
• Manufacturing method
• Batch size
• Mixing and homogenisation requirements
• Heating and cooling controls
• Filling process
• In-process quality checks
• Finished product specifications
• Retain samples
• Documentation and release procedures

For SPF products, consistency is especially important. The manufacturing process must support uniform distribution of UV filters and maintain the intended product structure. Poor scale-up can affect texture, stability, fill performance or product quality.

Working with a manufacturer experienced in sunscreen product development can help brands identify scale-up risks early and avoid delays close to launch.

Step 10: Prepare for Commercial Launch

A successful SPF launch depends on having the right product evidence, compliant claims and supply planning in place.

By the time the product is ready for launch, the brand should have confirmed the formula, packaging, testing, regulatory pathway, manufacturing process and launch claims. Commercial planning should also account for production lead times, packaging supply, stock forecasts, retail deadlines and marketing approvals.

Before launch, brands should check:

• Is the final formula approved?
• Has testing been completed and documented?
• Are claims supported by evidence?
• Has artwork been reviewed?
• Is packaging compatible with the formula?
• Are manufacturing and release specifications confirmed?
• Are regulatory obligations understood?
• Is the launch timeline realistic?
• Is there a plan for future production runs?

SPF products often require longer development timelines than standard skincare products. Brands should allow enough time for formulation, testing, regulatory review, packaging procurement and manufacturing.

How Long Does SPF Product Development Take?

SPF development timelines vary depending on complexity, testing requirements, packaging and regulatory pathway.

As a general guide, brands should expect an SPF product to take longer than a standard cosmetic formulation. Simple line extensions may move faster if the formulation pathway is clear, while custom SPF products with specific sensory, claims or packaging requirements may take significantly longer.

The biggest causes of delay are unclear briefs, late packaging changes, failed stability tests, SPF results below the target claim, ingredient supply issues and artwork or compliance revisions.

A realistic timeline should include room for reformulation and retesting. Building contingency into the development plan is usually more effective than trying to rush testing at the end.

Can Cosmetic Brands Create Custom Sunscreen Formulas?

Yes, cosmetic and skincare brands can create custom sunscreen formulas, but SPF development requires specialist formulation and regulatory expertise.

A custom SPF formulation can help a brand create a differentiated product with a specific texture, finish, claim profile or skin-benefit positioning. This may be valuable for brands that want to move beyond generic sunscreen formats and create a product that fits their range identity.

Custom SPF development can support:

• Daily facial sunscreen
• Mineral sunscreen
• Tinted SPF
• Moisturising SPF
• Sensitive skin SPF
• Sport or outdoor SPF
• Premium skincare-led SPF
• Water-resistant sunscreen
• Hybrid sunscreen formulas

However, custom does not mean unlimited flexibility. Sunscreen formulas must still meet technical, testing and compliance requirements. A strong development partner will help identify where the brand can differentiate and where the formula must stay within proven performance boundaries.

Common SPF Development Challenges

Most SPF development challenges come from trying to balance performance, feel, compliance and commercial requirements at the same time.

Common challenges include:

• Achieving the target SPF without compromising skin feel
• Reducing white cast in mineral or hybrid formulas
• Preventing pilling under makeup
• Managing greasiness or tack
• Maintaining stability over time
• Supporting broad-spectrum or water-resistance claims
• Selecting compliant and available ingredients
• Choosing packaging that protects the product
• Managing testing timelines
• Keeping cost of goods commercially viable

These challenges are manageable when they are considered early. Problems become more expensive when they are discovered after packaging is ordered, artwork is printed or launch commitments have been made.

Choosing an SPF Manufacturer in Australia

Choosing the right SPF manufacturer is one of the most important decisions in the development process.

SPF products require a manufacturer with the technical capability, quality systems and regulatory understanding to support sunscreen development from concept through to production. Brands should look for a partner that understands formulation, testing, compliance, scale-up and commercial realities.

When assessing an SPF manufacturer, ask:

• Do they have experience developing sunscreen products?
• Can they support custom SPF formulation?
• Do they understand Australian sunscreen requirements?
• Can they guide testing and evidence requirements?
• Do they have appropriate quality systems?
• Can they manufacture at the required scale?
• Can they support packaging and compatibility considerations?
• Can they help identify risks early?
• Do they understand both formulation and commercialisation?

For emerging brands, the right manufacturer can provide clarity and structure. For established brands, they can support innovation, scale, quality and speed to market.

How Delta Supports SPF Product Development

Delta supports brands through the technical and commercial stages of SPF product development, from formulation strategy through to manufacturing.

As an Australian formulation and manufacturing partner, Delta works with skincare and personal care brands to develop products that are commercially viable, technically robust and aligned with the brand’s market goals.

For SPF projects, this can include support across:

• Product concept development
• Custom SPF formulation
• Prototype development
• Ingredient and texture strategy
• Stability and compatibility planning
• Testing pathway guidance
• Packaging considerations
• Manufacturing scale-up
• Quality processes
• Commercial production

Developing sunscreen requires confidence at every stage. With the right formulation and manufacturing partner, brands can move through the process with greater clarity, fewer avoidable delays and a stronger foundation for launch.

FAQ: SPF Product Development

How do you develop an SPF product?

Developing an SPF product starts with a clear product brief, followed by regulatory pathway review, formulation strategy, prototype development, stability and compatibility testing, SPF and claims testing, packaging finalisation, manufacturing scale-up and commercial launch.

What testing is required for sunscreen in Australia?

Testing requirements depend on the product type and claims, but sunscreen products commonly require SPF testing, broad-spectrum testing, stability testing, microbiological testing, preservative efficacy testing, packaging compatibility testing and evidence to support any performance or marketing claims.

How long does SPF development take?

SPF development timelines vary depending on the formula complexity, packaging, testing pathway and regulatory requirements. Brands should allow more time than they would for a standard cosmetic product because sunscreen development often involves specialist testing, compliance review and potential reformulation.

Can cosmetic brands create custom sunscreen formulas?

Yes. Cosmetic and skincare brands can create custom sunscreen formulas with the right formulation and manufacturing partner. However, custom SPF products still need to meet relevant performance, testing, labelling and regulatory requirements.

What is required for TGA-listed sunscreen products?

TGA-listed sunscreen products need to meet applicable Australian requirements, including permitted ingredient rules, relevant sunscreen standards, evidence for claims, compliant labelling and inclusion in the Australian Register of Therapeutic Goods where required.

What makes SPF formulation difficult?

SPF formulation is difficult because the product must deliver reliable UV protection while still feeling pleasant on the skin. The formula must also remain stable, work with the chosen packaging, support claims and be suitable for commercial manufacturing.

When should brands speak to an SPF manufacturer?

Brands should speak to an SPF manufacturer as early as possible, ideally before finalising claims, packaging or launch timelines. Early technical input can help avoid unrealistic briefs, unsuitable packaging choices and compliance issues later in the process.

Developing an SPF Product Starts With the Right Partner

SPF product development is a technical journey that requires planning, testing and specialist expertise. From the first concept through to final manufacturing, every decision can influence the product’s performance, compliance, stability and commercial success.

For brands developing sunscreen in Australia, the best results come from building the right foundations early: a clear brief, a realistic development plan, a compliant claims strategy, suitable packaging and an experienced formulation and manufacturing partner.

Delta helps skincare and personal care brands navigate the SPF product development process with confidence, from concept and formulation through to testing, scale-up and commercial production.