How to Develop an SPF Product From Scratch

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.