Launching an SPF product can be a great way to scale your personal care brand, but navigating the complexities of Over-The-Counter (OTC) drug manufacturing can be daunting.
By partnering with an experienced manufacturer, you can bring a compliant, market-ready product to your customers.
Keep reading to learn:
- What consumers are looking for from their suncare
- What testing needs to be done for this OTC product
- What turnkey sunscreen production actually entails (and why it matters)
- How to add a sunscreen product to your line or transfer your existing formulation to another manufacturer.
The Changing Landscape of Sunscreen
More and more consumers read ingredient labels closely. Demand is rising for sun care that’s effective and safe for both skin and the environment.
To compete, it’s important that your brand meets these rising expectations. Consumers are actively looking for sunscreens that are:
- Skincare-Infused – Blended with antioxidants, hyaluronic acid, and niacinamide to provide extra protection and hydration.
- Mineral vs. Chemical Sunscreen – Utilizing naturally derived UV filters like Zinc Oxide and Titanium Dioxide to deflect rays, or carefully selected, compliant chemical filters.
- Reef- & Ocean-Friendly – Formulated without harmful chemicals like oxybenzone and octinoxate, which are known to cause coral bleaching.
- Paraben-Free & Sulfate-Free – Built without harsh preservatives or irritants, making them suitable for sensitive skin.
- Cruelty-Free – Developed without animal testing.
Customized Sunscreen to Fit Your Brand
For more than 40 years, FP Labs has provided manufacturing solutions for personal care brands. Our customizable, white-label sunscreens are formulated and tested in our onsite, FDA-registered lab by a chemistry staff with more than 60 years of combined experience.
Depending on your exact specifications, each stick sunscreen we produce can be formulated to be:
- Paraben-free
- Phthalate-free
- Not tested on animals
- Gluten-free
- Non-GMO
- Water-resistant
- Reef-safe
- Natural
- Invisible
How FP Labs Sources Ingredients for Sunscreen
Of course, your sunscreen formulation is only as good as the raw materials used to create it. Our team leverages an extensive, deeply vetted supply chain to source the right ingredients. Our procurement team works directly with trusted suppliers to utilize only high-quality ingredients.
Navigating FDA Regulations & SPF Testing
In the United States, sunscreen is classified and regulated as an Over-The-Counter (OTC) drug, which means strict oversight for the manufacturing process. As an FDA-registered sunscreen lab, FP Labs eliminates compliance risk.
Making compliant claims requires rigorous, clinical testing. We manage this intensive process for you, so every batch of your formulation meets the FDA’s OTC requirements:
- Microbiology Testing. Making sure the formula stays preserved and free from harmful bacteria, yeast, and mold throughout its shelf life.
- SPF Level Validation. Conducting strict testing to accurately determine and substantiate your product’s Sun Protection Factor.
- Broad-Spectrum Verification. Verifying the formula adequately blocks both UVA (aging) and UVB (burning) rays.
- Water Resistance Testing. Subjecting the formula to rigorous testing to legally claim water resistance.
The FP Labs Turnkey Process (From R&D to Packaging)
Scaling your brand shouldn’t require juggling half a dozen vendors. Our turnkey sunscreen production model provides a seamless, end-to-end manufacturing experience.
How our timeline breaks down:
- Research & Development. We start by understanding your brand vision, target demographic, desired active ingredients, and sensory profile (texture, scent, finish).
- Formulation and Testing. Our dedicated team of chemists engineer your custom formulation. With your approval, we begin the required stability, microbiological, and FDA-mandated testing.
- Blending & Filling. Following successful testing, we move to our GMP-compliant, state-of-the-art facility to scale up your formula, executing precise blending and filling protocols. Throughout the process, we adhere to strict quality assurance guidelines.
- Custom Containers. Packaging is the first thing your customer sees. We offer versatile, premium packaging options, including our Eco-Smart sunscreen containers, available in a wide variety of sizes and any Pantone color imaginable.
- Hit the Market. Your product is now ready for the marketplace!
The Rise of Sunscreen Sticks
Beyond traditional lotions and sprays, consumer demand for sunscreen sticks has grown. These sticks are a mess-free, travel-friendly way to apply and reapply throughout the day, over makeup or on high-exposure areas like the face, neck, and hands.
Our chemists specialize in engineering high-performance solid stick formulations that deliver lightweight, non-greasy finishes with reliable, proven protection.
Reduce Your Time to Market With FP Labs
Don’t let unknowns or regulatory hurdles stop you from scaling up. Partner with our passionate team at FP Labs to create an innovative, compliant, and effective SPF product your customers will love.
Because we conduct research and development, testing, and formulation on-site, we can reduce time-to-market!
Curious? Go ahead and explore our sunscreen capabilities. Interested in connecting with us? Reach out to our team, and let’s get started!
Frequently Asked Questions
What makes a sunscreen reef-friendly?
A reef-friendly sunscreen is formulated without active ingredients linked to coral reef damage, most notably oxybenzone and octinoxate. As a leader in reef-friendly sunscreen manufacturing, FP Labs specializes in creating highly effective formulations that protect the skin while complying with environmental bans.
Can FP Labs use my existing skincare formula?
Yes! Our chemistry staff can work, re-formulate, or revise and enhance your existing formula.
Keep in mind that adding UV filters changes the product’s chemical structure, so the new formulation will need to go through the full OTC stability and SPF testing process.
What are the minimum order quantities (MOQs) for custom sunscreen?
Because we specialize in helping brands scale, we offer flexible production runs tailored to your specific needs. For details on our current thresholds and how we can support your growth, visit our MOQs page.
How long does the custom formulation testing process take?
Because sunscreens are regulated as OTC drugs, the testing timeline is longer than standard cosmetics. Generally, the whole process, including R&D, stability testing, microbial screening, and clinical SPF validation, will take a minimum of six months before full-scale production begins.
This timing depends on the desired shelf life, which is typically 2 years. This requires three months of accelerated and six months of ambient stability testing. During this time, we’re usually also testing the formula for Broad-Spectrum and Water Resistance.