The multidisciplinary process of developing an alcohol- based hand sanitizer from scratch

Alcohol-based hand sanitizers (ABHS) have always been used in settings that require rigorous hand hygiene, but due to the COVID-19 pandemic, they are now also used by the general population. Considering the increase in demand for ABHS, the goal was to develop a formulation with plant-based and eco-friendly ingredients without compromising performance. Several formulations were developed, and ABHS F#8 was the final result. Skin hydration, transepidermal water loss, and pH were measured in vivo after application of this formulation. An improvement in skin hydration and capacity to retain water - and a normalization of the pH to 5.7 - were observed. The ABHS antimicrobial efficacy was assessed following European standards, and the formulation was classified as bactericidal, virucidal, and yeasticidal. To confirm the formulation's safety for daily use, two tests were performed: an in vitro skin irritation test and an ex vivo topical application followed by a cell viability test. F#8 was considered nonirritant and safe for the epidermis and dermis. The formulation was submitted to a sensory consumer evaluation in a hospital and was considered better than the benchmark. In conclusion, the authors developed a formulation with plant-based emollients that has antimicrobial activity while improving skin health and is sensorily pleasant to consumers.