Developing an SPF product involves more than creating a formula that feels good on the skin. Brands also need to consider how the product will be regulated, what claims they want to make, the testing required to support those claims, packaging and how the formula will move into commercial manufacturing.
The process generally starts with a clear product brief, followed by formulation development and refinement. From there, the product progresses through the appropriate testing and regulatory requirements before packaging is finalised and manufacturing begins.
A typical SPF development process includes:
- Defining the product concept, target SPF and intended claims
- Understanding the regulatory pathway
- Developing and refining the formulation
- Reviewing lab samples and making adjustments
- Completing the required stability and product testing
- Completing SPF, broad-spectrum and other relevant claims testing
- Finalising packaging and artwork
- Scaling the formulation for commercial manufacturing
- Completing manufacturing and quality requirements
- Preparing the finished product for market
For brands developing SPF products in Australia, involving an experienced formulation and manufacturing partner early can make the process easier to navigate. It allows formulation, testing, regulatory and manufacturing considerations to be addressed before decisions around packaging, claims or launch timing become difficult to change.
What Is SPF Product Development?
SPF product development is the process of taking a sunscreen idea from an initial brief through formulation, testing and commercial manufacturing.
For a brand, this means working through what the product should be, how it should feel, the claims it will make, the regulatory pathway it falls under and what is required to manufacture it commercially.
The process starts with a clear brief. Before formulation begins, the development team needs to understand the type of SPF product the brand wants to create, who it is for, the desired texture and finish, intended claims, packaging direction and commercial goals.
Step 1: Define the SPF Product Concept
The first step is deciding what you are actually trying to create.
A daily facial SPF will have a different brief from a water-resistant body sunscreen or tinted SPF. Before formulation begins, the brand and development team should be clear on the product type, target SPF, desired texture and finish, intended claims, packaging direction, target cost and launch goals.
A strong SPF brief should include:
- Product type and format
- Target SPF
- Desired texture and finish
- Intended claims
- Packaging direction
- Target cost
- Expected order volume
- Launch timing
A clear brief gives the formulation team a better starting point for development.
Step 2: Confirm the Regulatory Pathway
In Australia, the regulatory pathway depends on the type of sunscreen and how the product is intended to be used and marketed.
Sunscreen products do not all follow the same pathway. Depending on the product, its intended use and the claims being made, different regulatory requirements may apply.
Understanding this early can help inform decisions around formulation, testing, claims and artwork before those elements are finalised.
Brands should consider:
- How the product will be classified
- What requirements apply to the intended product
- What claims the brand intends to make
- What testing or evidence may be required
- What labelling requirements apply
For brands planning to sell in more than one market, requirements should also be considered for each intended region. A product developed for Australia may not necessarily follow the same pathway in another market.
Step 3: Build the Sunscreen Formulation Strategy
SPF formulation involves balancing the protection target with how the product needs to feel and perform in use.
The formulation team works from the product brief to develop a formula that takes into account the intended SPF, product format, texture and finish, ingredient requirements, stability, cost and future manufacturing.
These decisions need to be considered together. Changing one part of a formulation can affect other aspects of the finished product, which is why SPF development often involves testing and refinement rather than a single formulation attempt.
For brands, the focus should be on clearly communicating what the finished product needs to achieve rather than trying to specify every technical element of the formulation.
Step 4: Choose the Right UV Filter Approach
UV filters are the active ingredients responsible for a sunscreen’s UV protection.
The appropriate filter system will depend on the product being developed, the intended SPF, the desired product format and the regulatory requirements that apply.
Rather than selecting UV filters based on marketing preference alone, brands are generally better placed to start by defining the type of product they want to create, including its intended use, texture, finish and claims.
The formulation team can then determine an appropriate approach within the technical and regulatory requirements of the product.
Step 5: Develop and Refine Prototypes
Once the formulation direction has been established, the formulation team can prepare an initial lab sample for review.
The brand can then assess the sample and provide feedback before the formulation moves forward.
Feedback may relate to:
- Texture
- Spreadability
- Finish
- Fragrance
- White cast or transparency
- How the product feels on the skin
Several rounds of refinement may be required before the formulation is approved to move into the next stage of development.
Clear feedback helps the formulation team understand what needs to change between samples and keeps the development process moving in the right direction.
Step 6: Complete Stability Testing
Stability testing provides information about how a formulation performs over time under defined storage conditions.
Once a formulation reaches the appropriate stage of development, stability testing can be used to monitor changes in the product and identify whether further development work may be required.
The testing program will depend on the product and stage of development.
Testing may also include:
- Bacterial, yeast and mould testing
- Preservative efficacy testing
Packaging should also be considered during development so the intended pack can be assessed alongside the formulation before commercial production.
The results from testing can help determine whether the product is ready to continue through development or whether adjustments are required.
Step 7: Complete SPF and Performance Testing
SPF testing is used to determine whether the product supports the SPF it is intended to claim.
Depending on the product and its intended claims, additional testing may also be required.
This may include:
- SPF testing
- Broad-spectrum testing
- Water-resistance testing, where relevant
The testing pathway will depend on the product and claims being made.
If testing shows that the product does not support the intended SPF or claim, further formulation work and testing may be required. This is one reason testing requirements should be considered during development rather than only at the end of the project.
Step 8: Finalise Packaging and Artwork
Packaging needs to be considered alongside the formulation rather than as a purely visual decision.
The chosen packaging format needs to suit the product, filling process and intended use while also providing enough space for the required product information.
Packaging considerations may include:
- Packaging format
- Fill volume
- Dispensing method
- Compatibility with the formulation
- Decoration and artwork requirements
- Space for required labelling
Artwork should also be reviewed before printing to make sure the required product information and claims are presented appropriately.
For SPF products, brands should take particular care with claims and on-pack wording, as these need to align with the requirements that apply to the product.
Step 9: Scale Up to Manufacturing
Once the formulation is ready to move beyond the lab, it needs to be translated into a commercial manufacturing process.
A small lab sample and a commercial batch are produced using different equipment and at very different volumes.
During scale-up, the manufacturing team establishes how the formulation will be produced consistently at commercial scale. The manufacturing process may need to be refined before the product moves into routine production.
Depending on the project, this may include reviewing the manufacturing method, batch size, processing requirements, filling process and finished product specifications.
Planning for scale-up during development helps make the transition from formulation into commercial manufacturing more straightforward.
Step 10: Prepare for Commercial Launch
Before commercial production and launch, the key product requirements should be resolved.
This includes the formulation, required testing, regulatory pathway, packaging, artwork and manufacturing requirements.
Before launch, brands should confirm:
- The final formulation is approved
- Required testing has been completed
- Claims are supported
- Packaging and artwork are finalised
- Manufacturing requirements are confirmed
- Regulatory obligations have been addressed
Brands should also allow enough time for production planning, packaging supply and any development or testing work that remains outstanding.
How Long Does SPF Product Development Take?
There is no single development timeline for an SPF product.
Timing will depend on the formulation, regulatory pathway, required testing, packaging and whether further development work is required following testing.
SPF projects can involve additional development, testing and regulatory stages compared with some cosmetic products, so brands should factor these into launch planning from the beginning.
It is also useful to allow some flexibility in the development timeline in case a formulation needs further refinement or testing needs to be repeated.
Can Cosmetic Brands Create Custom Sunscreen Formulas?
Yes. Brands can develop custom SPF formulations, although the available options will depend on the product brief, regulatory pathway and testing requirements.
Custom development can give brands greater control over areas such as the product format, texture, finish and positioning.
However, some elements of the original brief may need to change as technical and regulatory requirements become clearer during development.
A good development process helps the brand understand where there is flexibility and where technical or regulatory requirements need to take priority.
Common SPF Development Challenges
SPF development often involves balancing several priorities at once.
A brand may want a high level of protection, a particular skin feel, specific claims, preferred ingredients, certain packaging and a target cost.
Not every requirement will necessarily work together exactly as originally imagined.
Discussing priorities early helps the formulation team understand which parts of the brief are essential and where there may be room to adjust.
It can also prevent important product decisions from being made too late in the development process.
Choosing an SPF Manufacturer in Australia
For an SPF project, it is important to work with a manufacturer that understands both sunscreen development and commercial manufacturing.
Brands should understand the manufacturer’s experience with SPF products, manufacturing capabilities, quality systems and how the development and testing process will be managed.
When speaking with a potential SPF manufacturer, consider asking:
- What experience do you have manufacturing SPF products?
- Can you support formulation development?
- How is required testing coordinated?
- What quality systems apply to SPF manufacturing?
- Can you support scale-up and commercial production?
- At what stage should packaging be introduced?
These conversations can help a brand understand the development process before committing to packaging, claims or launch dates.
How Delta Supports SPF Product Development
Delta works with skincare and personal care brands across SPF formulation development and commercial manufacturing.
Depending on the project, Delta can support brands through formulation development and refinement, stability testing, planning for required SPF testing, manufacturing scale-up and commercial production.
Connecting formulation and manufacturing within the same development process also means commercial production requirements can be considered earlier rather than being introduced only after the formula has been completed.
For brands, this creates a clearer path from the initial product brief through to manufacturing.
FAQ: SPF Product Development
How do you develop an SPF product?
SPF development generally starts with a clear product brief, followed by understanding the regulatory pathway, formulation development, testing, scale-up and commercial manufacturing.
What testing is required for sunscreen in Australia?
Testing requirements depend on the type of sunscreen and the claims being made. This may include SPF, broad-spectrum and water-resistance testing where relevant, alongside other testing required for the individual formulation.
How long does SPF development take?
There is no standard development timeline. Timing depends on the formulation, testing requirements, regulatory pathway, packaging and whether further development work is required.
Can cosmetic brands create custom sunscreen formulas?
Yes. Custom SPF development is possible, although the formulation needs to work within the technical, testing and regulatory requirements that apply to the product.
What is a TGA-listed sunscreen?
A TGA-listed sunscreen is a therapeutic sunscreen included in the Australian Register of Therapeutic Goods and identified by an AUST L number. Specific requirements apply to the ingredients, claims, evidence and labelling of listed sunscreen products.
What makes SPF formulation difficult?
SPF formulation involves balancing the required protection with factors such as product format, texture, finish, stability and manufacturing requirements. Changes made to one part of the formulation can also affect other aspects of the product.
When should brands speak to an SPF manufacturer?
Ideally, early in the development process, before claims, packaging and launch dates have been finalised.
Developing an SPF Product Starts With the Right Partner
Developing an SPF product involves formulation, testing, regulatory and manufacturing decisions that are best considered together.
For brands developing sunscreen in Australia, involving an experienced SPF manufacturer early can make it easier to understand the process and plan the path from the initial product brief through to commercial production.
Delta works with skincare and personal care brands across SPF formulation development, scale-up and manufacturing.
Ready to develop an SPF product?
Speak to Delta about your product brief and the next steps towards commercial manufacturing.