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Delta is an Australian contract manufacturer specialising in cosmetic, personal care, SPF and therapeutic products.

For more than 40 years, we have worked with brands to develop, manufacture, fill and pack products in Australia. Today, Delta works with businesses at different stages of growth, from brands developing their first product through to established companies looking for additional manufacturing capacity or a long-term production partner.

Our specialty is liquids and semi-solids, with formulation and manufacturing capability across creams, lotions, serums, gels, balms, oils, pastes, emulsions and ointments.

More Than 40 Years of Australian Manufacturing

Delta has been manufacturing products in Australia for more than four decades.

Over that time, our capabilities have expanded across cosmetic, personal care and regulated product categories, supported by formulation, R&D, manufacturing, filling, packing and quality teams.

Our manufacturing facilities in Somersby, New South Wales, support both cosmetic and therapeutic production. Delta holds TGA manufacturing licences for relevant liquids and semi-solids, allowing us to manufacture products including therapeutic sunscreens and other listed and registered products.

While the products and brands we manufacture have changed over the years, our role has remained much the same: helping brands turn a product brief or existing formulation into commercial production.

What Does Delta Manufacture?

Delta manufactures products across beauty, personal care, sun care and therapeutic categories.

Our main manufacturing categories include:

Sunscreen and SPF

We formulate and manufacture SPF products including:

• Facial sunscreens
• Body sunscreens
• Daily wear SPF
• Mineral sunscreens
• Chemical and hybrid sunscreens
• Tinted SPF
• Water-resistant and sport sunscreen
• SPF moisturisers
• Specialty sun protection products

Skincare

Our skincare manufacturing capabilities include:

• Cleansers
• Serums
• Moisturisers
• Eye products
• Masks
• Oils
• Balms
• Treatment products

Body Care

We manufacture a range of body care formats including lotions, creams, washes, oils, gels and targeted body treatments.

Haircare

Delta’s capabilities extend across hair and scalp care products in a range of liquid and semi-solid formats.

Self-Tan and After-Sun

We also manufacture self-tanning products and after-sun formats including lotions, gels, sprays and other face and body products.

Other Regulated and Personal Care Products

Our manufacturing capabilities also extend into areas such as topical ointments, oral medicines and pet care products where the appropriate manufacturing licences and requirements apply.

SPF Manufacturing at Delta

SPF is a major area of focus for Delta.

We are one of Australia’s leading SPF manufacturers, supporting brands across custom formulation, private label products and commercial sunscreen manufacturing.

Sunscreen manufacturing requires more than producing a cosmetic formula with UV filters added. The product needs to be developed within the regulatory, testing and manufacturing requirements that apply to its intended market.

Delta manufactures sunscreen and SPF products within TGA-licensed facilities in Australia.

Depending on the project, we can support brands with:

• Custom SPF formulation
• Reformulation of existing SPF products
• Private label SPF options
• Stability testing
• Planning for required external SPF testing
• Pilot scale-up where required
• Commercial manufacturing
• Filling and packing

For brands planning an SPF range, involving the manufacturing team early can also help clarify the product brief, intended claims, testing pathway and commercial production requirements before packaging and launch dates are locked in.

Three Ways to Work With Delta

Brands do not all come to us at the same stage.

Some have a product idea but no formulation. Others want to launch using an established formula. Some already own a completed formulation and simply need an experienced manufacturer to produce it at scale.

Delta offers three main ways to work together.

Private Labelling

Private labelling is suited to brands that want to launch using an established Delta formulation rather than developing one from scratch.

Brands can select from suitable existing formulations and work through the packaging, branding and commercial requirements needed to prepare the product for production.

This pathway can suit businesses that want a more streamlined development process or are looking to expand an existing range.

Product Development

Product development is for brands that want to create something specific to their brief.

The process starts by understanding the type of product, desired texture and finish, ingredient preferences, intended claims, target market, packaging direction and commercial requirements.

Our formulation team then develops lab samples for review and refinement.

Once the formulation reaches the appropriate stage, the product can move through relevant testing, scale-up where required and preparation for commercial manufacturing.

Contract Manufacturing

Contract manufacturing is suited to brands that already have an approved formulation and need a manufacturing partner to produce it commercially.

Delta can support production planning, bulk manufacturing, filling, packing, quality requirements and finished goods preparation.

This can include brands transferring an existing product to Delta or businesses looking for additional manufacturing capacity as production volumes increase.

From Product Brief to Commercial Production

The exact process depends on the project, but a new product developed with Delta generally starts with a product brief.

The brief helps our team understand what the brand wants to make, the intended product experience, packaging direction, market and commercial requirements.

From there, the project may move through:

1. Product brief and development planning
2. Lab sample development
3. Sample review and refinement
4. Relevant testing
5. Pilot scale-up where required
6. Commercial manufacturing
7. Filling and packing
8. Quality review and finished goods release

A brand may need support across the full process or only one part of it.

For example, an established brand may come to Delta with an existing formulation ready for manufacture, while another business may begin with only a product idea.

Who Does Delta Work With?

Delta works with both Australian and international brands.

Our clients range from businesses launching new products through to established companies with products already sold through major retail, pharmacy and beauty channels.

A brand might come to Delta because it wants to:

• Develop a new product
• Add SPF to an existing range
• Launch using an established private label formula
• Transfer an existing formulation to an Australian manufacturer
• Increase production volumes
• Expand into a new product category
• Find a long-term contract manufacturing partner

The right manufacturing pathway depends on what the brand already has and what it needs from us.

Australian Manufacturing With Delta

Delta manufactures in Australia and operates TGA-licensed facilities for relevant regulated products.

Our manufacturing capabilities cover the journey from formulation development through to commercial production, filling and packing.

For brands, this means the people developing the formulation and the teams responsible for manufacturing can work within the same wider process.

It also allows practical production requirements to be considered while a product is being developed rather than only once the formulation is complete.

Looking for an Australian Manufacturing Partner?

Whether you have an early product idea, an established formula or an existing range ready to scale, Delta can help you understand the manufacturing pathway that suits your project.

Speak to Delta about product development, private labelling or contract manufacturing.

Speak to Delta

The way a sunscreen feels, layers and sits on the skin can have a big impact on the overall product experience.

For some users, sunscreen may occasionally ball up or flake when applied with other skincare or makeup. This is commonly known as pilling. Formula stability is a separate consideration and relates to whether the product maintains its intended appearance, texture and consistency over time.

For brands developing SPF, understanding these behaviours can help inform formulation development, product testing and the intended user experience.

Why Does Sunscreen Pill?

Pilling happens when product gathers into small flakes or rolls on the surface of the skin instead of sitting smoothly.

It may become noticeable while sunscreen is being applied or when another product, such as foundation, is layered on top.

There is not always one simple cause.

Pilling can be influenced by:

• The sunscreen formulation
• The skincare products used underneath it
• Makeup applied over the top
• How much rubbing occurs during application
• How quickly products are layered
• Individual skin characteristics

This is why the same sunscreen may layer differently depending on the person’s routine and the products being used with it.

How Product Layering Can Affect SPF

A typical morning skincare routine may involve several products before sunscreen is applied.

Serums, moisturisers, facial oils, primers and sunscreen can all leave different materials on the skin. Adding makeup introduces another layer again.

When several products are applied together, the way those formulas interact can influence the finished result.

For example, pilling may become more noticeable when:

• Several layers are applied in quick succession
• One product has not had time to settle before the next is applied
• Products are repeatedly rubbed over one another
• A particular combination of skincare, SPF and makeup does not layer smoothly

For brands developing a daily facial sunscreen, this is worth considering because SPF is rarely used on completely bare skin.

Understanding how the product fits into an everyday skincare routine can help shape the desired texture, finish and application experience during development.

Do Silicones Cause Sunscreen Pilling?

Silicones are often associated with pilling, but they are not automatically the cause.

Silicones are commonly used in skincare and sunscreen formulations to influence areas such as spreadability, texture and skin feel.

A formula containing silicones can still layer smoothly.

Pilling is better considered in the context of the complete formulation and the other products being used alongside it.

Film-forming ingredients, polymers and other materials can also influence the way products behave when layered.

For brands, focusing on the overall product experience is generally more useful than trying to avoid one ingredient purely because it has been associated with pilling.

Application Technique Can Make a Difference

How sunscreen is applied can also influence how it sits on the skin.

Repeated rubbing may disturb skincare layers underneath and make pilling more noticeable.

Allowing products to settle between layers and applying sunscreen evenly can help create a smoother finish.

If pilling occurs, consumers may find it helpful to:

• Allow skincare products time to settle before applying sunscreen
• Apply products in even layers
• Avoid excessive rubbing once the sunscreen has been spread
• Notice whether pilling only occurs with certain product combinations
• Follow the sunscreen’s application directions

Using less sunscreen than directed is not the ideal way to address pilling. Sunscreen should still be applied according to the product instructions.

The Skin Can Also Influence How Products Layer

The products being used are only one part of the application experience.

Individual skin characteristics may also influence how skincare and sunscreen behave once applied.

Factors such as skin hydration and oil levels can affect the way products spread and sit on the skin.

This helps explain why one person may notice pilling with a particular combination while another person does not.

For brands, considering different skin types and common skincare routines during product evaluation can provide useful feedback about the way a sunscreen feels and layers in everyday use.

What Does Formula Stability Mean?

Formula stability is different from pilling.

Pilling happens during application. Stability relates to how the formulation performs over time.

Many sunscreen products are emulsions, meaning different components of the formulation are brought together to create a uniform finished product.

The aim during formulation development is to create a product that maintains its intended appearance, texture and consistency as it progresses through the appropriate testing program.

Several factors can influence formula stability, including:

• The formulation itself
• Ingredient interactions
• Manufacturing process
• Storage conditions
• Product format
• Packaging considerations

These areas are considered during development rather than being assessed only once a product reaches commercial production.

How Is Formula Stability Assessed During Development?

A sunscreen can look and feel right when a lab sample is first produced, but the development team also needs information about how the formulation performs over time.

Stability testing provides that information.

The formulation is monitored under defined storage conditions and assessed against the requirements established for the product.

The exact testing program will depend on the formulation and stage of development.

Results can help the development and quality teams understand whether the product is ready to continue through development or whether further review is required.

This is part of the normal development process for many cosmetic and personal care products.

Pilling and Formula Stability Are Different Considerations

Although both can influence the way a consumer experiences a sunscreen, pilling and formula stability should not be treated as the same issue.

Pilling relates to how the product behaves during application and layering.

Formula stability relates to whether the formulation maintains its intended characteristics over time under defined testing conditions.

A sunscreen that pills when combined with a particular skincare product is not necessarily unstable.

Likewise, stability testing does not tell a brand everything about how a sunscreen will behave underneath moisturiser, primer or makeup.

Both areas can be considered during development, but they provide different information about the finished product.

Developing SPF With the User Experience in Mind

For brands, the first step is being clear about how the sunscreen is intended to fit into the consumer’s routine.

A daily facial SPF designed to sit comfortably underneath makeup may have different product goals from a sunscreen intended for sport, swimming or outdoor use.

A useful SPF brief might include preferences around:

• Texture
• Finish
• Spreadability
• Absorption
• White cast
• Makeup compatibility
• Overall skin feel

These details give the formulation team a clearer picture of the experience the brand wants to create.

During sample review, feedback should also be as specific as possible.

Instead of simply saying a sunscreen “doesn’t layer well”, it is more useful to explain what happened, when it happened and which other products were being used.

That information gives the formulation team more context when reviewing the sample.

How Brands Can Assess SPF Layering

Brands do not need to become formulation specialists to provide useful feedback.

Simple real-world observations can be helpful during development.

When reviewing a sunscreen sample, consider:

• How easily does it spread?
• How does it feel once applied?
• Does the finish change after a few minutes?
• How does it sit over common skincare products?
• How does makeup apply over the top?
• Does additional rubbing affect the finish?
• Does the experience match the original product brief?

The goal is not to test every possible skincare combination.

It is to understand how the product behaves in the types of routines it is being designed for.

SPF Development at Delta

Delta works with skincare and personal care brands across SPF formulation development and commercial manufacturing.

During development, brands can review lab samples and provide feedback on areas such as texture, finish, spreadability and the way the product sits on the skin.

Stability testing can also provide information about how the formulation performs over time under defined storage conditions.

Considering both the formulation and the intended user experience during development gives the team a clearer understanding of what the finished product is expected to achieve before moving towards commercial manufacturing.

FAQ: SPF Pilling and Formula Stability

Why does sunscreen ball up on the skin?

Sunscreen pilling can be influenced by the sunscreen itself, products layered underneath or over it, application technique and individual skin characteristics.

Can skincare underneath sunscreen cause pilling?

Yes. The way different products interact when layered can influence whether pilling occurs. Allowing skincare products time to settle before applying sunscreen may help.

Do silicones cause sunscreen to pill?

Not necessarily. Silicones are commonly used in skincare and SPF formulations and do not automatically cause pilling. The complete formulation and the products being layered together are more relevant.

Why does sunscreen pill under makeup?

Pilling under makeup can occur when the skincare, sunscreen and makeup layers do not sit smoothly together. Application technique and repeated rubbing may also contribute.

Is pilling the same as formula separation?

No. Pilling happens during application on the skin. Formula stability relates to how the product maintains its intended appearance, texture and consistency over time.

How can brands assess sunscreen layering during development?

Brands can review how the sunscreen spreads, settles, feels and behaves over common skincare products and underneath makeup. Specific feedback gives the formulation team useful information during sample refinement.

Developing an SPF Product?

Delta works with brands across SPF formulation development, stability testing, scale-up and commercial manufacturing.

Speak to Delta about your SPF product, desired user experience and manufacturing requirements.

Speak to Delta

Water resistance is an important consideration for sunscreen products designed to be worn while swimming, exercising or spending extended time outdoors.

But a sunscreen cannot simply be described as water resistant because the formula is designed to stay on the skin. The claim needs to be supported by appropriate testing, and the requirements can differ depending on where the product will be sold.

For brands developing sunscreen, understanding water resistance testing early can help shape the product brief, testing plan and claims before packaging and artwork are finalised.

What Does Water Resistance Mean in Sunscreen?

A water-resistant sunscreen is one that has demonstrated an appropriate level of SPF protection after being exposed to water under defined test conditions.

It does not mean the sunscreen is waterproof or that it will remain on the skin indefinitely.

During water resistance testing, sunscreen is applied to test subjects and the treated skin is exposed to controlled periods of water immersion. SPF is then assessed following the required water exposure.

The results are used to determine whether the product can support the intended water-resistance claim.

This distinction is important for brands. A high SPF result before water exposure does not automatically mean the product can make a water-resistance claim. The product needs to be tested using the method required for the intended market.

What Do 40 and 80 Minutes of Water Resistance Mean?

The terms 40 minutes and 80 minutes are commonly associated with sunscreen water-resistance testing, particularly in the United States.

They refer to the amount of water immersion the sunscreen has undergone during testing before its SPF is assessed.

An 80-minute water-resistant sunscreen has therefore been tested following a longer total period of water immersion than a product carrying a 40-minute claim.

This does not mean someone can apply an 80-minute sunscreen and ignore reapplication instructions for 80 minutes under every circumstance.

Activities such as towel drying can remove sunscreen, and consumers still need to follow the directions provided on the label.

40-Minute Water Resistance

Under the FDA testing framework, a 40-minute water-resistance claim involves two 20-minute periods of water immersion, with a drying period between them.

After the required immersion and drying process has been completed, the sunscreen’s SPF is assessed.

If the product meets the applicable requirements, its label can state that it is water resistant for 40 minutes.

80-Minute Water Resistance

For an 80-minute claim, the water-immersion process is extended.

The FDA method uses four 20-minute periods of water immersion, again with defined drying periods between them.

The SPF is then assessed following the full 80 minutes of water exposure.

For brands, the important point is that 40 and 80 minutes are tested claims. They are not simply descriptions chosen for the packaging.

How Is Sunscreen Water Resistance Tested?

Water resistance testing is carried out under controlled conditions so that the product can be assessed consistently.

The exact procedure depends on the standard and market being used, but the process generally follows the same basic principle:

1. The sunscreen is applied. A defined amount of the product is applied to the test area according to the relevant test method.
2. The product is allowed to settle on the skin. The test method specifies how the product is applied and the time allowed before water exposure.
3. The test area is immersed in water. Subjects complete the required periods of controlled water immersion.
4. Drying periods are included. Depending on the method, periods outside the water separate the immersion cycles.
5. SPF is assessed following water exposure. Testing determines the level of SPF protection demonstrated after the required immersion period.
6. The result is reviewed against the intended claim. The results are assessed according to the standard and market requirements that apply to the product.

The purpose is to create a controlled way of assessing how the sunscreen performs after water exposure.

Real-world conditions will naturally vary, which is why consumers still need to follow the application and reapplication directions on the finished product.

What Happens During the Water Immersion Stage?

The water immersion part of the test is controlled rather than simply asking a participant to swim normally.

The relevant method sets requirements for how the water exposure takes place, including the immersion periods and conditions used during testing.

For FDA water-resistance testing, the process involves 20-minute periods of moderate activity in water followed by defined periods out of the water. The number of cycles depends on whether the product is being tested for a 40 or 80-minute claim.

International testing methods also provide standardised approaches to water immersion so that water resistance can be assessed alongside SPF testing.

For brands, the detailed testing procedure will usually be managed by the specialist sunscreen testing facility. The more useful question during development is which claim the product is being designed to support and which testing pathway applies to the intended market.

Which ISO Standards Apply to Water Resistance Testing?

International standards provide recognised methods for assessing sunscreen performance.

ISO 16217:2020 sets out a water-immersion procedure used when determining the water resistance of sunscreen products. It is designed to be used alongside the SPF testing method in ISO 24444.

ISO 18861:2020 provides a method for evaluating the percentage of water resistance. It compares the SPF measured before water immersion with the SPF measured after the defined water exposure.

These standards provide testing methods. The claim a brand can ultimately make still depends on the requirements of the market where the sunscreen will be sold.

That distinction matters because Australia, the United States and other markets do not necessarily use water-resistance claims in exactly the same way.

Water Resistance Requirements in Australia

Australia uses the Australian/New Zealand Sunscreen Standard, AS/NZS 2604:2021, for new sunscreen products.

The standard incorporates international testing methods but also includes Australian-specific requirements.

One important difference is that Australian water-resistance claims are not limited to the 40 and 80-minute wording commonly seen in the United States.

Under the current Australian standard, the maximum water-resistance duration that can be claimed is linked to the SPF of the product.

A sunscreen with an SPF of 30 or above may support a water-resistance claim of up to four hours where the appropriate testing requirements are met. Products with lower SPF levels have lower maximum claim durations.

This is why a brand developing sunscreen for Australia should not choose its desired water-resistance claim based purely on what it has seen on products in another market.

The intended SPF, testing results and requirements of the Australian standard all need to be considered.

For therapeutic sunscreens, the sponsor is responsible for holding appropriate evidence to support the water-resistance claim made for the product.

Water Resistance Requirements in the United States

In the United States, sunscreens are regulated by the FDA as over-the-counter drug products.

Where a brand wants to make a water-resistance claim, the product must meet the FDA’s applicable water-resistance testing requirements.

The recognised claims are:

Water Resistant (40 minutes) and Water Resistant (80 minutes).

The label also needs to provide the applicable reapplication directions.

Terms such as waterproof, sweatproof and sunblock are not permitted under the FDA sunscreen framework because they can give consumers the impression that the product provides a level or duration of protection that has not been demonstrated.

For Australian brands considering the US market, this is another reason claims and packaging should be reviewed for the intended region rather than simply carrying Australian wording across to the US product.

Does a Higher SPF Mean Better Water Resistance?

No. SPF and water resistance describe different aspects of sunscreen performance.

SPF relates to the level of sun protection demonstrated by the product under the applicable SPF test.

Water resistance considers how the product’s SPF performs following a defined period of water immersion.

A high-SPF sunscreen therefore does not automatically have a high level of water resistance.

If a water-resistance claim is planned, the product needs to go through the relevant testing pathway.

When Should Water Resistance Be Considered During SPF Development?

Ideally, before the formulation has been finalised.

If a brand wants to develop a sunscreen for sport, swimming, outdoor activity or another use where water resistance is important, that should form part of the original product brief.

The formulation team can then consider the intended SPF, desired product experience and water-resistance goal during development.

Testing should also be factored into the project timeline. If the product does not support the intended claim, further formulation work and repeat testing may be required.

It is also worth confirming the intended markets early. A product being developed only for Australia may follow a different claim and testing strategy from one intended for both Australia and the United States.

Water Resistance Testing and Delta

Delta works with skincare and personal care brands across SPF formulation development and commercial manufacturing.

When water resistance is part of the product brief, it can be considered during formulation development alongside the intended SPF, product format, claims and target market.

Depending on the project, Delta can support formulation development, lab samples, stability testing, manufacturing scale-up and planning for the required external SPF and water-resistance testing.

Specialist SPF and water-resistance testing is completed through appropriate testing facilities, with the required pathway determined by the product and intended market.

Discussing the water-resistance goal early gives the brand and formulation team a clearer understanding of what the finished product is intended to achieve before claims and packaging are locked in.

FAQ: SPF Water Resistance Testing

What does water resistant SPF mean?

It means the sunscreen has undergone testing to assess its SPF following a defined period of water exposure. The exact claim and testing requirements depend on the market.

What does 80 minutes water resistant mean?

In the United States, an 80-minute water-resistance claim means the sunscreen has been tested after a total of 80 minutes of water immersion using the applicable FDA procedure. It does not mean the sunscreen is waterproof.

What is the difference between 40 and 80-minute sunscreen?

The difference is the amount of water immersion completed during the required test. Under the FDA method, a 40-minute claim involves two 20-minute immersion periods, while an 80-minute claim involves four.

Can sunscreen be labelled waterproof?

No. Sunscreens eventually wear or wash off. In the United States, terms such as waterproof and sweatproof are not permitted sunscreen claims. Australian guidance also does not accept waterproof or sweatproof wording for sunscreens.

How long can sunscreen be labelled water resistant in Australia?

Under the current Australian standard, the maximum claim depends on the product’s SPF and the results of the required testing. Products with SPF 30 or above may support water-resistance claims of up to four hours where the applicable requirements are met.

Is water resistance testing the same as SPF testing?

They are connected, but they are not the same claim. Water-resistance testing assesses sunscreen performance following defined water exposure, while SPF testing establishes the product’s sun protection factor according to the relevant method.

Does every sunscreen need water resistance testing?

Not every sunscreen needs to make a water-resistance claim. If a brand wants to claim that the product is water resistant, the claim needs to be supported by the testing required for the intended market.

Developing a Water-Resistant SPF?

If water resistance is part of your sunscreen concept, it is worth discussing the intended claim and market while the product is still being developed.

Delta works with brands across SPF formulation development, scale-up and commercial manufacturing, with external testing requirements considered as part of the development pathway.

Speak to Delta

Talk to Delta about your SPF product, water-resistance goals and commercial manufacturing requirements.

Speak to Delta