Techno‐economic analysis of kenaf sunscreen formulated with encapsulated <scp>UV</scp> filters: From laboratory batch to pilot scale

Abstract The growing demand for multifunctional skincare has driven interest in incorporating plant‐based bioactive substances into cosmetic formulations. This study presents a techno‐economic analysis (TEA) of a novel sunscreen formulated with kenaf ( Hibiscus cannabinus L.) seed oil (KSO) carrier system and tocotrienol‐rich fraction (TRF). The process was simulated and scaled up 15‐fold using Aspen HYSYS V14, while capital and operating costs were estimated with Aspen Capital Cost Estimator. Unit production cost, return of investment (ROI), payback period, and net present value (NPV) are among the financial metrics used to evaluate profitability. The economic evaluation considered raw materials, labor, utilities, and startup costs. Numerical results show that an annual net profit of RM 1.55 million can be achieved with a minimum selling price of RM 0.55/g and a payback period of two years. Sensitivity and uncertainty analyses indicate that raw material costs (KSO and TRF) are the main factors affecting profitability, followed by labor, working capital, and capital investment. Even under cost fluctuations of ±25%, the process remains economically feasible. This resulted in a pilot‐scale production capacity of approximately 20 metric tons per year. These results suggest that scaling up the production of sunscreen using a KSO‐based carrier system is both technically and economically viable, supporting its potential as a sustainable and innovative solution in skincare, in line with Sustainable Development Goal (SDG) 12: Responsible Consumption and Production.