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 Testing Explained

Water resistance is an important consideration for sunscreens designed for swimming, sport or other activities where the product may be exposed to water or sweat.

In Australia, 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 meet the requirements of the Australian/New Zealand Sunscreen Standard.

For brands developing sunscreen, understanding the intended water-resistance claim early helps the formulation and manufacturing teams plan the product and its testing pathway.

What Does Water Resistant Sunscreen Mean?

A water-resistant sunscreen has been tested to assess how its SPF performs after a defined period of water immersion.

It does not mean the product is waterproof or that it will provide the same level of protection indefinitely while swimming or exercising.

During testing, sunscreen is applied according to the relevant test method and exposed to controlled periods of water immersion. SPF is then assessed following that water exposure.

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

For brands, the main thing to understand is that SPF and water resistance are related, but they are not the same claim.

A sunscreen can achieve a particular SPF without automatically being able to claim water resistance.

How Does Water Resistance Work in Australia?

Sunscreens supplied in Australia need to meet the applicable requirements of the Australian/New Zealand Sunscreen Standard, AS/NZS 2604:2021.

For new therapeutic sunscreens included in the Australian Register of Therapeutic Goods, or ARTG, from 1 July 2024, the 2021 standard applies.

Under the Australian standard, the maximum water-resistance claim is linked to the SPF demonstrated by the product.

For sunscreen products with:

• SPF 8 to less than SPF 15: a maximum water-resistance claim of 40 minutes
• SPF 15 to less than SPF 30: a maximum claim of 2 hours
• SPF 30 or above: a maximum claim of 4 hours

This means a brand developing an SPF 50+ sunscreen may aim for a water-resistance claim of up to four hours, but that claim still needs to be supported by the required testing.

The maximum claim is not automatically given to the product because of its SPF.

How Is Sunscreen Water Resistance Tested?

Water-resistance testing is carried out under controlled conditions using recognised test methods.

The exact procedure is managed by the specialist sunscreen testing facility, but for a brand the basic process is relatively simple to understand.

1. The Sunscreen Is Applied

A defined amount of sunscreen is applied to the test area according to the relevant method.

2. The Product Is Exposed to Water

The test subjects complete controlled periods of water immersion.

The total immersion time depends on the water-resistance claim being assessed.

3. SPF Is Assessed After Water Exposure

Following the required water immersion, SPF testing is carried out.

This assesses the sunscreen’s SPF after it has been exposed to the defined water conditions.

4. The Results Are Reviewed

The testing results are then assessed against the requirements of the Australian standard and the claim the brand intends to make.

For brands, the detailed testing procedure does not need to be understood in the same way a testing laboratory would understand it.

The important questions are what water-resistance claim the product is being developed for and what testing is required to support it.

What Role Do ISO Standards Play?

The Australian/New Zealand Sunscreen Standard incorporates internationally recognised ISO testing methods.

For water resistance, ISO 16217 sets out the water-immersion procedure used when assessing sunscreen water resistance.

ISO 18861 provides a method for evaluating the percentage of water resistance by comparing sunscreen performance before and after water immersion.

These standards provide the testing methods used within the wider Australian framework.

For a brand, it is useful to distinguish between the testing method and the claim that ultimately appears on the product.

The testing may use an ISO method, but the finished sunscreen still needs to meet the Australian requirements that apply to the intended claim.

Does SPF Determine Water Resistance?

SPF influences the maximum water-resistance duration that can be claimed in Australia, but a high SPF does not automatically mean a sunscreen is water resistant.

For example, an SPF 50+ product may be eligible for a water-resistance claim of up to four hours under the Australian standard.

It still needs appropriate testing to support the water-resistance claim being made.

This is why SPF testing and water-resistance testing should be treated as different parts of the sunscreen testing pathway.

Does Every Sunscreen Need to Be Water Resistant?

No.

Not every sunscreen needs a water-resistance claim.

A daily facial sunscreen designed primarily for everyday wear may have a different brief from an SPF developed for swimming, sport or extended outdoor activity.

Whether water resistance should form part of the product brief depends on how the brand wants the sunscreen to be used and positioned.

If water resistance is important to the product concept, it should be discussed early in development rather than added as a claim once the formulation is complete.

What About Secondary Sunscreens?

This is particularly important for brands developing products such as moisturisers that also contain SPF.

In Australia, some secondary sunscreens can be excluded from therapeutic goods legislation when they meet specific criteria.

For certain secondary sunscreen categories, including qualifying moisturising skincare and sunbathing skincare products, one of the requirements for exclusion is that the product is not presented as water resistant.

If the product does not meet the relevant exclusion criteria, it may instead fall within the therapeutic sunscreen pathway and need to be included in the ARTG.

This is why the intended SPF, claims and product positioning should be considered together when developing a sunscreen product.

Who Is Responsible for the Water-Resistance Claim?

For therapeutic sunscreens in Australia, the sponsor is responsible for holding appropriate evidence to support the claims made for the product.

This includes water-resistance claims where they are made.

The product also needs to meet the testing and labelling requirements that apply under the Australian sunscreen framework.

For a brand new to SPF manufacturing, this does not mean you need to organise or interpret the testing yourself.

Your formulation, manufacturing, regulatory and external testing partners can help establish what is required for the individual product.

When Should Water Resistance Be Considered?

Ideally, it should be part of the original SPF brief.

If the product is intended for swimming, sport, beach use or another situation where water resistance is important, tell the formulation team at the beginning of development.

Useful things to establish early include:

• Target SPF
• Intended water-resistance claim
• Intended product use
• Product format
• Desired texture and finish
• Australian regulatory pathway

This gives the formulation team a clearer understanding of what the finished sunscreen is intended to achieve.

It also allows the required external testing to be considered within the wider development timeline.

What Happens if the Intended Claim Is Not Supported?

Testing provides information about whether the product supports the intended water-resistance claim.

If the required result is not achieved, the product and testing pathway will need to be reviewed.

Depending on the circumstances, further formulation work or repeat testing may be required before the intended claim can be used.

This is one reason brands should avoid finalising claims and packaging too early in SPF development.

Water Resistance and SPF Development at Delta

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

If water resistance is part of the product brief, the intended claim can be considered during formulation development alongside the target SPF, product format and intended use.

Depending on the project, Delta can support:

• SPF formulation development and refinement
• Lab samples
• Stability testing
• Planning for required external SPF and water-resistance testing
• Manufacturing scale-up
• Commercial manufacturing

SPF and water-resistance testing that requires specialist external testing facilities is planned as part of the wider development pathway.

For brands, discussing the intended claim early gives everyone involved a clearer understanding of the product being developed before packaging and launch plans are finalised.

FAQ: Water Resistance Testing in Australia

What does water resistant sunscreen mean?

It means the sunscreen has been tested to assess its SPF after a defined period of water immersion and has met the requirements needed to support the water-resistance claim being made.

What is the maximum water-resistance claim in Australia?

The maximum depends on the product’s SPF. Under the Australian standard, SPF 30 and above can support a water-resistance claim of up to four hours where the required testing criteria are met.

Does SPF 50+ automatically mean four hours water resistant?

No. SPF 50+ allows for a maximum claim of up to four hours, but the product still needs appropriate testing to support the water-resistance claim.

Can an SPF 15 sunscreen be water resistant?

Yes, where the applicable testing requirements are met. Under the Australian standard, products with SPF 15 to less than SPF 30 can support a maximum water-resistance claim of two hours.

Is water-resistance testing the same as SPF testing?

No. SPF establishes the sun protection factor of the product. Water-resistance testing assesses SPF following defined periods of water exposure.

Does every sunscreen need water-resistance testing?

No. Water-resistance testing is relevant when a brand intends to make a water-resistance claim.

Can a secondary sunscreen claim water resistance?

It depends on the product and regulatory pathway. For some secondary sunscreen categories, being presented as water resistant means the product will not meet the criteria for exclusion from therapeutic goods legislation. The individual product should therefore be assessed before the claim is finalised.

Developing a Water-Resistant Sunscreen?

If water resistance is part of your SPF concept, it is worth discussing the intended claim 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, intended water-resistance claim and commercial manufacturing requirements.

Speak to Delta