Launching a sunscreen that not only protects skin but also aligns with the rising global demand for clean, eco-friendly beauty. That’s the promise of mineral sunscreen — a formula powered by natural minerals rather than synthetic chemicals.

Mineral sunscreen is a physical sunblock that uses zinc oxide or titanium dioxide to reflect UV rays off the skin, offering broad-spectrum protection without irritation. Unlike chemical sunscreens, it begins working the instant it’s applied and is often preferred for sensitive skin or natural skincare lines.

As more consumers demand “reef-safe” and non-toxic beauty, understanding mineral sunscreen’s formulation and performance has become crucial for every skincare brand. In this article, we’ll explore how it works, what makes it special, and how Zerun Cosmetic can help you create your own high-performing mineral sunscreen product that stands out in the market.

What Makes Mineral Sunscreen Different from Chemical Sunscreen

Mineral sunscreen protects the skin by forming a physical barrier that reflects UV rays, while chemical sunscreen absorbs them and converts UV into heat. This fundamental difference defines performance, texture, and skin compatibility.

According to data from the Environmental Working Group (EWG) and American Academy of Dermatology (AAD):

• Zinc Oxide and Titanium Dioxide in mineral sunscreens block up to 95–98% of UVB rays.
• Chemical filters like Avobenzone absorb about 90–95%, but they break down faster under sunlight.
• Around 30–40% of people with sensitive skin report irritation from chemical filters, while fewer than 5% react to mineral ones.

So if your skin gets red, itchy, or stings easily after sunscreen — that’s a big hint to go mineral.

Consumer Preferences

Recent data shows that 68% of global consumers prefer mineral sunscreen for its safety and eco-friendly perception. The trend is especially strong in the premium skincare and baby care segments.

Why Brands Are Switching

For brands, mineral sunscreen offers transparency and sustainability — values consumers now expect. It also positions products well within “clean beauty” marketing frameworks.

Mineral sunscreen differs not just in chemistry but also in consumer trust and brand positioning potential.

Key Ingredients Used in Mineral Sunscreen Formulas

Mineral sunscreens are formulated using naturally derived mineral filters that sit on top of the skin to physically block and reflect UV rays, rather than being absorbed like chemical filters. The two main active ingredients—zinc oxide and titanium dioxide—are both recognized by the U.S. FDA and the EU Commission as safe and effective for broad-spectrum UV protection.

Zinc Oxide

Zinc oxide is one of the most versatile and widely used ingredients in mineral sunscreens. It provides true broad-spectrum protection, meaning it effectively blocks both UVA and UVB rays. Its unique ability to scatter, reflect, and absorb ultraviolet radiation makes it an essential ingredient for high-performance formulations.

Typically, zinc oxide particles range from 100 to 200 nanometers in size. This size range ensures that the product spreads smoothly without leaving an overly white residue, while still maintaining excellent UV-blocking capacity.

In most formulations, the concentration of zinc oxide falls between 5% and 25%, depending on the desired SPF level and the product texture. Lower percentages (around 5–10%) are common in daily moisturizers or tinted sunscreens, whereas higher levels (15–25%) are used in sport or outdoor protection formulas that require longer-lasting coverage.

Beyond UV protection, zinc oxide also has soothing and anti-inflammatory properties, making it ideal for sensitive or acne-prone skin. It’s non-comedogenic, gentle on the skin barrier, and often used in baby sunscreens and dermatologist-recommended brands.

Titanium Dioxide

Titanium dioxide is another essential mineral filter known for its strong UVB protection and partial coverage of the UVA spectrum. It works primarily by reflecting and scattering UV rays on the skin’s surface.

The typical particle size for titanium dioxide used in sunscreens is around 200 to 300 nanometers. This range offers an optimal balance between transparency and protection—allowing formulations to appear less white on the skin while still delivering effective UV defense.

Titanium dioxide is generally used in concentrations ranging from 2% to 15%. It’s particularly valued in lightweight or cosmetic-style sunscreens, where a smoother and more elegant skin finish is desired. Many brands combine titanium dioxide with zinc oxide to achieve full UVA and UVB protection without compromising texture or visual appeal.

Additionally, titanium dioxide is photostable, meaning it doesn’t degrade easily under sunlight. This helps ensure consistent SPF performance throughout wear. However, since it doesn’t fully cover the UVA1 spectrum (the longer wavelengths of UVA), formulators often rely on zinc oxide or other complementary ingredients to close that protection gap.

The Synergy Between the Two

In most modern mineral sunscreen formulations, zinc oxide and titanium dioxide are used together. This combination allows brands to deliver a balanced, broad-spectrum product that protects effectively from both UVA and UVB rays while maintaining a pleasant cosmetic finish.

By adjusting the particle size distribution, coating technology, and dispersion method, manufacturers can fine-tune the final product’s texture, transparency, and SPF performance—creating formulations that are not only highly protective but also comfortable, wearable, and suitable for all skin tones.

Supporting Components

Formulations often include emollients, natural oils, antioxidants, and silicone alternatives to improve spreadability and finish.

Clean Label Considerations

Modern mineral sunscreens avoid microplastics and nano-sized particles to maintain a “natural” market claim.

The right combination of minerals and emollients defines both performance and sensory appeal in modern mineral sunscreen.

How Mineral Sunscreen Protects the Skin from UV Rays

Mineral sunscreen protects your skin by sitting on the surface and acting like a tiny mirror that reflects and scatters harmful UV rays. Its main ingredients, zinc oxide and titanium dioxide, form a physical barrier that blocks both UVA (aging) and UVB (burning) rays. Unlike chemical sunscreens, it doesn’t absorb UV light or create heat, making it safer for sensitive skin and kids. This natural shield starts working immediately after application, preventing sunburn, dark spots, and premature aging while keeping your skin calm and protected.

The Physics of Reflection

Each mineral particle acts like a tiny mirror. Zinc oxide offers broad UVA and UVB coverage, while titanium dioxide enhances UVB reflection.

UV Protection Efficiency Table

Long-Term Skin Benefits

Continuous use helps prevent photoaging, hyperpigmentation, and DNA damage, making mineral sunscreen ideal for daily skincare lines.By reflecting UV rays rather than absorbing them, mineral sunscreens offer a safer, more stable form of sun protection.

Benefits of Choosing Mineral Sunscreen for Sensitive Skin

If you have skin that easily stings, reddens, or breaks out, mineral sunscreen can be a total game changer. Because it’s hypoallergenic and made with gentle ingredients like zinc oxide and titanium dioxide, it works well for all skin types — especially sensitive, reactive, or acne-prone skin.

Why It’s Gentler

Unlike chemical sunscreens that sink into the skin and absorb UV rays, mineral formulas stay on the surface. They act as a soft, protective shield that reflects the sun’s rays instead of triggering a chemical reaction. This means there’s less chance of irritation, no burning sensation, and fewer breakouts.

Mineral sunscreens are also non-comedogenic, meaning they won’t clog pores or trap oil — a major plus for people who struggle with acne or rosacea. Many formulas are fragrance-free and alcohol-free, reducing the risk of flare-ups even further.

Key Consumer Pain Points Solved

For skincare brands targeting the sensitive-skin market, mineral sunscreens provide a rare mix of safety, effectiveness, and trustworthiness — qualities modern consumers truly value.

The Role of Zinc Oxide and Titanium Dioxide in Sun Protection

When it comes to sunscreen, two ingredients stand out as gold standards for broad-spectrum protection and skin safety: zinc oxide and titanium dioxide. These naturally occurring minerals are the foundation of mineral (or physical) sunscreens, offering effective UV defense without the drawbacks of many chemical filters. Below, we’ll break down their unique properties, functions, and the science behind why they’re so trusted.

How Mineral Sunscreens Work

Unlike chemical sunscreens — which absorb UV rays and convert them into heat through a chemical reaction — zinc oxide and titanium dioxide physically block or scatter UV light before it penetrates the skin.

When applied to the skin, these minerals form a protective barrier that reflects and diffuses both UVA and UVB rays, acting much like microscopic mirrors.

• Zinc Oxide (ZnO): Offers the most comprehensive broad-spectrum coverage.
• Titanium Dioxide (TiO₂): Excellent at blocking UVB and short UVA rays, often used in combination with zinc oxide for full-spectrum protection

Chemical Nature & Mechanism

Zinc oxide is an inorganic compound that sits on the skin’s surface and provides uniform protection against both UVA and UVB radiation. It is a photo-stable, non-irritating, and non-comedogenic ingredient, making it suitable for sensitive, acne-prone, and baby skin.

UV Coverage

• UVA1 (340–400 nm): Excellent protection
• UVA2 (320–340 nm): Excellent protection
• UVB (280–320 nm): Excellent protection

Zinc oxide is one of the only single active ingredients capable of offering true broad-spectrum coverage on its own.

Benefits Beyond Sun Protection

• Anti-inflammatory properties: Helps calm redness and irritation — useful in products for rosacea or post-procedure skin.
• Wound healing: Promotes repair and acts as a mild astringent.
• Gentle formulation: Ideal for individuals who react to chemical sunscreens.

Chemical Nature & Mechanism

Zinc oxide is an inorganic compound that sits on the skin’s surface and provides uniform protection against both UVA and UVB radiation. It is a photo-stable, non-irritating, and non-comedogenic ingredient, making it suitable for sensitive, acne-prone, and baby skin.

Formulating Mineral Sunscreen: Balancing Texture, Coverage, and Stability

Creating a high-performance mineral sunscreen is both a science and an art. While zinc oxide and titanium dioxide form the backbone of UV protection, crafting a formula that feels elegant on the skin, spreads evenly, and remains stable over time requires meticulous formulation expertise. The challenge lies in achieving the perfect balance between texture, coverage, and stability — the three pillars of a successful mineral sunscreen.

The Challenge of Mineral Sunscreen Formulation

Mineral sunscreens work differently from chemical ones. Instead of absorbing UV radiation, zinc oxide and titanium dioxide physically reflect and scatter light. This means that the particles must be uniformly distributed across the skin’s surface to ensure even protection. However, because these mineral particles are opaque and dense, they can easily cause undesirable effects like whiteness, uneven spreading, or heavy texture.

For formulators, the key goal is to maintain broad-spectrum protection while making the sunscreen lightweight, non-greasy, and invisible on the skin.

Achieving the Right Texture

Texture is often the biggest consumer concern with mineral sunscreens. Traditional formulations were thick, chalky, and left a visible white cast — especially on darker skin tones. Modern formulation technology, however, has evolved dramatically.

One of the most important advances is the use of micronized or nano-sized zinc oxide and titanium dioxide. By reducing particle size, formulators can significantly improve the transparency and smoothness of the product. These smaller particles scatter light more evenly, allowing the sunscreen to blend into the skin without leaving a noticeable residue.

To further enhance the sensory experience, formulators often include silicones, emollient esters, and lightweight natural oils (like jojoba or squalane). These ingredients create a silky glide and help the product spread evenly. Some brands also add film-forming polymers that improve water resistance while keeping the finish breathable and comfortable.

The ideal mineral sunscreen texture is one that feels light and non-sticky, absorbs quickly, and leaves the skin looking natural — not overly matte or greasy.

Ensuring Complete UV Coverage

While texture is essential for user comfort, UV coverage remains the non-negotiable foundation of any sunscreen. Both zinc oxide and titanium dioxide offer powerful UV defense, but they protect against different parts of the spectrum.

Zinc oxide is a true broad-spectrum filter, capable of blocking UVA and UVB rays effectively, including the long-wave UVA1 range responsible for premature aging. Titanium dioxide, on the other hand, offers excellent protection against UVB and short UVA2 rays but less so against longer UVA wavelengths.

For this reason, formulators typically combine both minerals to achieve complete broad-spectrum protection. The exact ratio depends on the target SPF and desired skin feel. For example, a lightweight facial sunscreen might rely on a higher percentage of titanium dioxide for its smooth texture, while a sensitive-skin product could emphasize zinc oxide for maximum UVA defense and soothing benefits.

In addition to the active minerals, dispersion quality is critical. Each particle must remain evenly suspended in the base to prevent clumping or uneven coverage. High-shear mixing techniques and specialized dispersants help maintain a stable, uniform film when applied to the skin.

Maintaining Formula Stability

Stability is another key challenge in mineral sunscreen development. Because zinc oxide and titanium dioxide are inorganic powders, they can interact with other ingredients in the formula, leading to separation, oxidation, or reduced SPF performance over time.

To ensure stability, formulators use coating technologies. The mineral particles are often coated with silica, alumina, or dimethicone to prevent them from reacting with oils or water in the emulsion. These coatings also improve dispersibility, helping the sunscreen stay uniform and effective throughout its shelf life.

Stabilizing agents such as antioxidants (like vitamin E or green tea extract) are also added to prevent oxidation, while preservatives ensure microbiological safety. Maintaining an appropriate pH range is equally important to prevent degradation and maintain texture consistency.

Moreover, water-resistant formulations often use film-formers and wax blends to keep the product intact during sweating or swimming without compromising comfort. Each adjustment requires careful testing — a change in emollient or emulsifier can alter both SPF value and texture.

Balancing Aesthetic Appeal and Performance

The success of a mineral sunscreen in today’s market doesn’t depend only on its SPF number — it’s also about how it feels and looks on the skin. Consumers increasingly expect sunscreens to double as skincare or makeup products.

To meet this demand, formulators incorporate tinted pigments, hydrating agents, and skin-loving additives such as niacinamide, hyaluronic acid, or ceramides. These not only improve the skin feel but also help neutralize the white cast caused by mineral actives. A well-formulated tinted mineral sunscreen can blend seamlessly into multiple skin tones while providing even coverage and a radiant finish.

In short, the modern mineral sunscreen must achieve three things simultaneously:

1. Comprehensive UV protection (both UVA and UVB)
2. A lightweight, elegant texture
3. Long-term formula stability and consumer safety

Balancing these elements requires deep technical expertise and continuous innovation.

The Science of a Balanced Mineral Sunscreen

A balanced mineral sunscreen is the result of thoughtful formulation choices. The UV filters (zinc oxide and titanium dioxide) provide reliable physical protection. The emulsifiers and emollients determine how it spreads and feels on the skin. Coating technologies ensure the stability and safety of the actives. Every element — from particle size to preservative system — contributes to how effectively the sunscreen performs and how pleasant it is to wear.

Formulating mineral sunscreen is no longer just about achieving a high SPF — it’s about creating a product that people want to wear every day. By mastering the balance between texture, coverage, and stability, formulators can produce sunscreens that not only defend the skin from harmful rays but also enhance the user’s skincare experience. The future of sun protection lies in combining scientific precision with cosmetic elegance, and mineral filters like zinc oxide and titanium dioxide remain at the heart of this evolution.

Why Brands Are Switching to Reef-Safe and Eco-Friendly Sunscreens

Over the past few years, you’ve probably noticed more sunscreen bottles with labels like “reef-safe,” “ocean-friendly,” or “eco-conscious.” This isn’t just a marketing buzzword — it’s part of a global shift toward sustainable skincare.

The Environmental Wake-Up Call

Studies have found that some chemical UV filters, especially oxybenzone and octinoxate, can harm marine life. Even tiny amounts — we’re talking just one drop in 6.5 Olympic swimming pools of water — can damage coral DNA, cause bleaching, and disrupt fish development.

According to the National Ocean Service (U.S.), around 14,000 tons of sunscreen wash off swimmers into oceans every year. That’s a big reason places like Hawaii, Palau, and Thailand have already banned non-reef-safe sunscreens.

Traditional vs. Reef-Safe Sunscreens

Why Brands Are Making the Switch

• Consumer Demand: A 2024 Nielsen survey found that 68% of skincare shoppers prefer eco-friendly or reef-safe products.
• Regulations: More coastal regions are banning harmful chemical filters. Brands must adapt or lose market access.
• Brand Reputation: Consumers increasingly link sustainability with trustworthiness — especially Gen Z buyers.
• Ingredient Innovation: New formulations now use non-nano zinc oxide that offers clear finishes, eliminating the old “white cast” problem.

How Zerun Cosmetic Helps Brands Develop Their Own Mineral Sunscreen Line

Zerun Cosmetic specializes in OEM/ODM skincare manufacturing with expertise in sunscreen formulation.

We offer:

• Free formulation design and sample support
• Custom branding and packaging solutions
• Compliance with EU, FDA, and ASEAN standards

Partnering with Zerun Cosmetic allows brands to launch safe, effective, and market-ready mineral sunscreens effortlessly.

Conclusion

Mineral sunscreen has evolved from a niche product to a global skincare standard — valued for its safety, eco-friendliness, and effectiveness. As consumer trust shifts toward clean formulations, brands that innovate early will capture long-term loyalty.

If your brand aims to develop a high-quality, customized mineral sunscreen line, Zerun Cosmetic offers end-to-end solutions — from formulation to packaging — ensuring your product meets international standards and customer expectations.