Thailand Sunscreen OEM Manufacturing: Choosing the Right Direction for Your Brand

Why Sunscreen Is More Complex Than Serums or Moisturizers

With serums or moisturizers, you can start from sensory preference: fast absorption, not greasy, pleasant scent. Sunscreen is the opposite—you start from technical constraints, then optimize the feel within what remains possible.

Three main constraints:

• **SPF rating is a measured result, not a marketing claim.** SPF and PA (or PPD, UVA-PF depending on the testing method) are determined through testing on the finalized formula itself. Changing filter ratios, changing the base oil, even changing the film-former can shift the results.
• **The filter system makes up the largest share of formula cost.** In many sunscreen lines, UV-blocking ingredients represent the highest proportion of raw material costs. This is why a sunscreen product and a moisturizer of the same volume have vastly different cost structures.
• **Permitted filter ingredients vary by market.** Each region has its own list of allowed UV-filtering substances and concentration limits. A formula valid in one market may need adjustment in another.

Practical consequence: if you plan to sell the same SKU in multiple countries, mention it from your first meeting. Choosing a filter system compatible with all target markets from the start is far easier than reformulating after packaging is printed. This is the biggest difference between manufacturing sunscreen cosmetics and standard skincare production.

ODM, OEM, or Full Custom: Three Paths and Their Trade-offs

When working with a manufacturer, you typically face three routes. Choosing the right one from the start saves you many sample iterations.

**ODM — using the manufacturer's existing base formulas.** The manufacturer already has sunscreen bases from previous production runs, usually with testing data on those bases. You select a base, make sensory adjustments where possible (fragrance, color, a few supporting actives), then focus your budget on packaging and branding. This is the fastest and lowest technical-risk path for your first product.

**OEM — the manufacturer produces according to your formula or specifications.** Suitable when you already have a formula from a previous project, or have specific requirements about which ingredients to include or avoid. You have more control, but you're responsible for the feasibility of your specs.

**Full custom — jointly developing an entirely new formula.** Choose this when you want a genuine differentiation point—for example, a unique texture or filter system. In exchange, you'll run more sample rounds, spend more on formula development, and your timeline depends on testing results.

One simple principle: if this is your brand's first product and you don't have sales data yet, start with ODM. Save your formula development budget for the second SKU, once you know what customers actually want.

Filter Systems and Texture: The Decisions You Must Finalize

Most of the discussion in a sunscreen project revolves around two questions: which filter system to use, and what texture you want.

On filter systems, the most practical classification is:

• **Mineral/physical system:** typically zinc oxide and titanium dioxide. Many brands choose this for sensitive skin and children's lines. The challenge is the white cast and heavy feel if not handled well.
• **Chemical/organic system:** delivers a lightweight texture, easier to achieve higher SPF ratings, but permitted ingredients and concentration limits must be checked by market.
• **Hybrid system:** most common in today's market because it balances SPF performance with sensory experience.

On texture, speak to your manufacturer in consumer language, not technical jargon: does your customer want a matte or dewy finish, subtle brightening or completely transparent, will it go under makeup, what climate is it for?

Prepare two to three reference products on the market to describe the feel you want—not to copy, but so both sides understand quickly. Accept trade-offs early: higher SPF and stronger water resistance means it's harder to keep a lightweight feel. Choose one key strength to communicate rather than demand everything.

Packaging: Decide Early Because It's Linked to Your Formula

Many brand owners push packaging decisions to the final stage. With sunscreen, this is an expensive mistake because packaging and formula are interdependent.

Considerations:

• **Tubes** are the common choice for cream and milk sunscreens: economical, good product protection from air, easy to carry. The downside is difficulty creating a premium feel without investing in surface finishing.
• **Airless or pump bottles** convey premium positioning and better dosing control, but the formula viscosity must fall within the working range of the pump. A formula that's too thick will clog the pump or dispense unevenly.
• **Spray or liquid formats** open up a different customer segment, but bring their own requirements around shipping and customs declaration, especially with volatile components.

One often-overlooked factor: material compatibility. Certain sunscreen ingredients can interact with the inner lining of packaging over time. Stability testing should be run on your final packaging, not just in lab bottles. If you change packaging suppliers after testing is complete, ask your manufacturer whether retesting is needed.

One note on MOQ: for OEM/ODM production, the standard minimum is 1,000 units per SKU. Factor this into your cash flow and sales plan from the beginning, not later.

Documentation, Testing, and How You Talk About the Product

The documentation phase is where projects often get delayed—not because it's difficult, but because it starts too late.

Typical requirements include:

• **SPF testing** on your finalized formula, using the method your target market accepts. This is the only basis for claiming an SPF number on your label.
• **Stability and packaging compatibility testing**, run on your actual packaging.
• **Microbial and safety testing** per target market requirements.
• **Product information dossier** for regulatory filing in the importing country.

On procedures: cosmetics registration rules, labeling requirements, and supporting documentation differ by country and change over time. Treat this article as reference only—verify with your regulatory authority or customs broker in your target market. Your manufacturer and production partner provide technical documentation by product type at order time; filing documentation in the importing country is typically the brand owner's responsibility or that of your chosen service provider.

Finally, how you communicate about your product. Keep your messaging within what testing has proven, and avoid absolutes. Sunscreen labels and advertising are scrutinized far more heavily than other skincare categories, so get the wording right from the start—it's cheaper than correcting it later.

Working with a Partner: Checklist and Common Mistakes

Before sending a request to a manufacturer, prepare these six pieces of information. They significantly reduce back-and-forth cycles:

1. **Target markets** — which countries you'll sell in, which are priority. 2. **Customer profile** — skin type, age range, intended retail price point. 3. **SPF target and desired benefits** — target SPF, water resistance needed, brightening or not. 4. **Must-have and must-avoid ingredients** — according to your brand positioning. 5. **Packaging direction** — format, volume, finish investment level. 6. **Sales plan** — sales channels, expected number of SKUs in year one.

The three most common mistakes:

• **Finalizing packaging before finalizing the formula.** Printing happens, then you discover the formula doesn't work with the pump, or the SPF test result differs from what you printed.
• **Approving samples based on one person's impression.** Have at least five to seven people from your target customer group test the product for several days under real conditions.
• **Launching too many SKUs at once.** One SPF, one texture, perfect execution, then expand. If later you want to enter supplements or drinks, that's a separate project with its own regulations—not an extension of your sunscreen line.

If you want one partner to oversee everything from formula through packaging to documentation rather than assembling a lab, designer, and manufacturer yourself, a production management partner like 5FINE (5fineglobal.com) is one option worth exploring alongside other choices.