Turnkey Aerosol & OTC Sunscreen Solutions from Formula to Shelf
Navigate complex FDA OTC monograph standards, zero-residue clean formulations, and high-speed precision aerosol packaging. Longway provides end-to-end ODM solutions powered by on-site HPLC/GC analytical testing and 300,000+ daily unit automated capacity.
Request Formulation Consultation
Why Brands Struggle with Aerosol & OTC Scaling
Producing beauty sprays and OTC drugs is fundamentally different from standard skincare. Without specialized chemical engineering, brands face massive failure rates.
Regulatory & OTC Monograph Pitfalls
Sunscreen sprays and antiperspirants sold in North America must comply with strict FDA 21 CFR drug standards. Lack of cGMP registration or NDC listing delays customs clearance and leads to product seizures.
Valve Clogging & Formula Degradation
Sub-par matching between valve, actuator, and propellant causes white spots, valve blockage, pressure leakage, and uneven aerosol dispersion during the consumer’s usage cycle.
Stringent Multi-Region VOC Caps
California CARB, OTC State Model Rules, and EU eco-regulations impose strict volatile organic compound caps. Formulating high-performance dry shampoos or hairsprays under 55% VOC requires deep R&D.
The Longway Aerosol & Spray Delivery Platform
We don't just fill cans — we engineer complete delivery systems integrating propellant, valve mechanics, active ingredient stability, and spray cone ergonomics.
Micro-Mist Particle Sizing
Laser diffraction droplet testing guarantees an ultra-fine, uniform mist cone that delivers instant absorption, non-greasy skin feel, and zero inhalation discomfort.
Bag-on-Valve (BoV) 360°
100% continuous 360-degree spraying powered by eco-friendly compressed air or nitrogen. Formulations remain vacuum-sealed from propellants for clean and preservative-free claims.
Pre-Tested OTC Monograph
Battle-tested broad-spectrum SPF 30 & SPF 50+ formulations verified under FDA OTC rules, water-resistant for 80 minutes, reef-friendly, and validated with USP 51 challenge testing.
In-House HPLC & GC Audit
Audit-trail chromatography instruments ensure active sunscreen agent uniformity, residual benzene elimination, and accurate batch stability testing in real time.
High-Growth Formulations Ready for Customization
Ultra-Sheer Broad Spectrum SPF 50+ Mist
- FDA OTC & NDC Registered Ready
- 80-Minute Water Resistant
- Reef Friendly (Oxybenzone-Free)
- Non-Greasy & Quick Drying
Zero-Residue Volume Dry Shampoo Spray
- Low-VOC Formulation Options
- Ultra-Fine Micro-Rice Starch
- Instant Sebum Absorption
- Benzene-Free Lab Verified
Extreme Hold Lace Melt & Wig Mist
- Quick Dry Without Flaking
- Sweat & Humidity Resistant
- Gentle on Sensitive Scalp Edges
- Clean Water-Rinse Removal
Cooling Aloe & Centella Repair Mist
- 100% Bag-on-Valve Separation
- Eco-Friendly Nitrogen Propellant
- Continuous 360° Easy Spritz
- Ideal for Post-Sun & Sensitive Skin
Rigorous Pharmaceutical-Grade Testing On-Site
Our quality control goes far beyond simple physical testing. We run a dedicated OTC analytical center equipped with computerized chromatography systems complying with global audit integrity standards.
From Product Concept to Global Retail Distribution
A transparent 5-step operational framework designed to compress speed-to-market while guaranteeing zero regulatory surprises.
Market Brief & Regulatory Scoping
Align on target regional jurisdictions (US FDA, EU, ASEAN, GSO), VOC constraints, and claims.
Formulation & Valve Matching
Lab sample creation, actuator angle calibration, and formula-propellant compatibility screening.
Accelerated Stability & Challenge
USP 51 preservative efficacy, 3-month thermal stress testing, and packaging pressure validation.
Automated Cleanroom Filling
High-speed pressure-leak testing, water bath immersion inspection, and automated weight checks.
DG Logistics & Compliance Dossier
Full dangerous goods packaging certification, MSDS preparation, and smooth customs import clearance.
Ready to Engineer Your Next Market-Leading Spray?
Speak directly with our cosmetic formulation chemists and regulatory engineers. Request benchmark laboratory samples, stability dossiers, or schedule an audit of our 40,000 m² facility.
Request Formulation Consultation