Synthesis and Evaluation of a ZnO-Chitosan Adduct for Safe and Sustainable Enhanced Ultra-Violet (UV) Sunscreens Protection

Chitosan (Ch), a natural polysaccharide, is known for its biocompatibility, biodegradability, and various beneficial properties, including antioxidant and antibacterial activities. The objective of this study is to investigate the functionalization of zinc oxide (ZnO) with chitosan to develop a novel ZnO@Ch adduct for use in cosmetic formulations, specifically as a sun protection agent. The functionalization was achieved through ionotropic gelation, which enhanced the stability and reduced the photocatalytic activity of ZnO, thereby improving its safety profile for skin applications. FTIR spectroscopy confirmed the successful functionalization, while TGA and DSC characterized the thermal properties and stability. The Zeta potential and particle size analyses demonstrated improved stability of ZnO@Ch across various pH levels compared to uncoated ZnO. The structure of the obtained adduct was also confirmed by SEM analysis. The ZnO@Ch adduct exhibited enhanced stability at neutral and slightly alkaline pH values, reduced photocatalytic activity compared to pure ZnO, and had lower cytotoxicity in 3T3 cells compared to pure ZnO, particularly at higher concentrations. The ZnO@Ch adduct provided a higher Sun Protection Factor (SPF) and UVA Protection Factor (UVA-PF) than pure ZnO, indicating enhanced UV protection. The adduct’s ability to provide higher SPF at lower ZnO concentrations offers economic and environmental benefits, aligning with sustainable product design principles. Future studies will focus on optimizing the formulation and testing the efficacy and safety at higher concentrations to fully realize its potential as a natural, eco-friendly sunscreen ingredient.