Development of multipurpose sunscreen for the sensitive areas of the face and design of the manufacturing process

Abstract

The limited availability of sunscreens for the sensitive areas of the face led to the development of sunscreens for eye contour (eye cream sunscreen) and lips (lip sunscreen), followed by the design of their manufacturing process. It was encouraged by the growth of the sun protection market, due to the increasing awareness of risks related to sun exposure, which are of special importance in the eye contour and lips, as these are areas with less protection capability. For this reason, the market trends were identified through market analysis and bibliographic search, allowing the identification of consumer needs, which resulted in the development of broad-spectrum sunscreens with sun protection factor 50 that moisturize and soothe the skin, providing an enhancing effect that enables layering with makeup, and, in the case of the lip sunscreen, giving a nude color that lasts a minimum of 2 hours; additionally, environmentally friendly packaging were designed, with refillable containers made of bamboo, recycled plastic, and aluminium. According to these needs, the quality factors and their performance indices were defined, whereby the eye cream sunscreen would be a pseudoplastic oil-in-water nanoemulsion with low eye-stinging ability, and the lip sunscreen would be a water-in-oil emulsion-based suspension with thixotropic behaviour, solid-like at room temperature, with a pleasant taste and smell. UV filters, humectants, and emollients were chosen as active ingredients to meet the quality factors, they were specified in terms of concentration and characteristics of each, and subsequently, their manufacturing processes were designed by selecting equipment and establishing batches of 150 kg of each product, with 2 batches per year for the eye cream sunscreen and 4 batches for the lip sunscreen