Dual-Particle Synergy in Bio-Based Linseed-Oil Pickering Emulsions: Optimising ZnO–Silica Networks for Greener Sunscreens

The development of mineral, biodegradable sunscreens that can offer both high photoprotection and long-term colloidal stability, while limiting synthetic additives, presents a significant challenge. A linseed-oil nanoemulsion co-stabilised by ZnO nanoparticles and the eco-friendly surfactant Appyclean 6552 was formulated, and the effect of incorporating fumed silica/alumina (Aerosil COK 84) was evaluated. A central composite response surface design was used to ascertain the oil/ZnO ratio that maximized the in vitro sun protection factor at sub-300 nm droplet size. The incorporation of Aerosil at concentrations ranging from 0 to 2 wt.% resulted in a transformation of the dispersion from a nearly Newtonian state to a weak-gel behavior. This alteration was accompanied by a reduction in the Turbiscan Stability Index. Microscopic analysis has revealed a hierarchical particle architecture, in which ZnO forms Pickering shells around each droplet, while Aerosil aggregates bridge neighboring interfaces, creating a percolated silica scaffold that immobilizes droplets and amplifies multiple UV scattering. The findings demonstrate that coupling interfacial Pickering armor with a continuous silica network yields a greener, physically robust mineral sunscreen and offers a transferable strategy for stabilizing plant-oil emulsions containing inorganic actives.