Description
What is Aerosil?
Aerosil is the widely used trade name for fumed silica. Its INCI name is Silica. It is a fine, white, fluffy powder made from silicon dioxide. It has no smell and no colour.
Aerosil does not add active skin benefits to a formula. Instead, it controls how a product feels, flows, and looks on the skin. Formulators call it a rheology modifier. That means it changes the thickness and texture of a formula without changing its chemistry or active ingredients.
It is used in creams, gels, sunscreens, loose powders, foundation bases, serums, and lip products. A very small amount goes a long way. At just 1 to 3 percent, it can turn a thin liquid into a smooth, spreadable gel. In Pakistan, you may also see it written as Aerocil or Aerosil 200. Both refer to the same cosmetic-grade ingredient.
Why Formulators Use Aerosil
Controls Thickness Without Heating
Unlike waxes or fatty alcohols, Aerosil works at room temperature. You do not need to melt or heat it before adding it to your formula. Disperse it into your oil or water phase and it begins to thicken immediately. This saves time and energy during production.
Creates a Matte, Dry Finish
Aerosil absorbs excess oil on the skin surface. This gives products a smooth, matte, and non-greasy finish. It is a key ingredient in mattifying moisturisers, oil-control sunscreens, and lightweight BB creams. Customers feel the difference immediately when they apply the product.
Keeps Powders Free-Flowing
In loose powders and powder foundations, particles tend to clump together in humid conditions. Aerosil prevents this by coating the powder particles and keeping them separate from each other. This is especially important for manufacturing in Pakistani cities where heat and humidity are high throughout the year.
Stops Pigments and Particles from Settling
In sunscreens, tinted moisturisers, and serums with active particles, ingredients can settle to the bottom of the formula over time. Aerosil creates a light network structure inside the formula that holds particles in place. This keeps your product stable and uniform from the first use to the last.
Works in Both Oil and Water Phases
The hydrophilic grade of Aerosil can be dispersed into both water-based and oil-based systems. It is compatible with most emulsifiers, preservatives, and active ingredients used in standard cosmetic production. You will not face instability or separation problems in most standard formulas.
Very Effective at Low Usage Levels
You do not need to use a large amount of Aerosil to get results. Even at 0.5 to 2 percent, it delivers noticeable thickening and texture improvement. This makes it very cost-efficient per production batch.
How to Use Aerosil in Your Formulations
Handling Note:
Aerosil is an extremely light and fluffy powder. It becomes airborne very easily when handled. Always wear a dust mask and eye protection when weighing and working with this ingredient. Avoid working near open fans or air vents. Use a slow-speed mixer or gentle manual stirring when dispersing it into your formula. High-speed mixing will cause clumping and air entrapment in the final product.
Recommended Levels of Usage by Product Type:
| Product Type | Aerosil in Formula (by weight) |
| Cream or Lotion (thickening) | 0.5% to 2% |
| Gel (clear or opaque) | 1% to 5% |
| Sunscreen (suspension aid) | 0.5% to 2% |
| Loose Powder (anti-caking) | 0.5% to 3% |
| Foundation or BB Base | 1% to 3% |
| Serum or Light Fluid | 0.2% to 1% |
| Lip Product | 0.5% to 2% |
Target pH:
Aerosil is stable across a wide pH range of 3.5 to 9.0. It performs well in both acidic and alkaline formulas. Set your target pH based on the type of product you are making, not based on the Aerosil. Use citric acid to bring the pH down and a diluted sodium hydroxide solution to bring it up.
Formulation Build Order:
- Weigh Aerosil carefully. Pre-mix it with a small portion of your oil phase using a spatula until all lumps are broken.
- If working in a water-based formula, disperse Aerosil into a small amount of glycerin or water first and mix until smooth.
- Add the pre-dispersed Aerosil to your main formula with gentle stirring.
- Continue stirring slowly at low speed until the texture becomes uniform throughout.
- Let the batch rest for 10 to 15 minutes. Aerosil develops its full thickening effect after it settles into the formula.
- Adjust pH to your target range using citric acid.
- Add fragrance, preservative, and any active ingredients at room temperature.
What You Can Make With Aerosil
- Mattifying moisturisers and face creams
- Clear and opaque face gels
- Sunscreens with SPF 30 and SPF 50
- Loose face powder and pressed powder
- Compact powder base
- BB cream and tinted moisturiser
- Oil-free foundation
- Serum with active particles or pigments
- Lip balm and lip gloss
- Body lotion
- Primer base
Why Order From Stexol
COA With Every Batch
Every batch of Aerosil from Stexol comes with a Certificate of Analysis. You can check the grade, purity, and appearance before you start your production. Consistent raw material means consistent finished products. No surprises, no wasted batches.
No Minimum Order Pressure
We supply in small and bulk quantities so that you can start small and test your formulas without having to overstock. Scale up your orders as your production grows.
Tiered Pricing for Larger Orders
Larger order volumes come with better pricing. Message us on WhatsApp with the volume you need and we will send you the best available price for your batch size.
Same-Day Dispatch
Orders confirmed before the daily cutoff are dispatched the same day. No delays. No waiting around for your production schedule.
Frequently Asked Questions
Q: What is the difference between Aerosil and Aerocil?
A: They are the same ingredient. Aerosil is the correct trade name. Aerocil is a common spelling variation used in Pakistan. Both refer to fumed silica with the INCI name Silica.
Q: Can I use Aerosil to thicken a water-based serum?
A: Yes. Pre-disperse it in a small amount of glycerin or water first, then add it to your serum with gentle stirring. Start at 0.5% and increase until you reach the thickness you want.
Q: Is Aerosil safe for leave-on products like creams and lotions?
A: Yes. Aerosil is widely used in leave-on cosmetic products at recommended usage levels. It is a well-established functional ingredient in the personal care industry.
Q: Does Aerosil affect the transparency of a gel formula?
A: Yes. At higher percentages above 3%, Aerosil will make a gel appear cloudy or white. If you need a clear gel, keep the usage level at 1% or below and test before scaling up your batch.
Q: How should I store Aerosil to keep it in good condition?
A: Store it in a tightly sealed container in a cool, dry place away from moisture and humidity. Never leave it in open containers. Aerosil absorbs moisture from the air, which can reduce its effectiveness in formulas.
Order Now
Looking to buy Aerosil for your next formula? Small and bulk quantities available. COA included. Same-day dispatch. Bulk pricing available.
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