Replacing Emulsifiers with Gelation: A Surfactant-Free Approach to Emulgel Formulation Using Polyvinyl Alcohol

Conventional emulgels require emulsifiers to stabilize oil and water, which may cause skin irritation and complicate formulations. This study aimed to develop a surfactant-free emulgel using polyvinyl alcohol (PVA) as both gelling and stabilizing agent.

A 3² factorial design evaluated the effects of PVA concentrations (2 %, 4 %, 10 %) and olive oil ratios (10 %, 20 %, 40 %) on emulgel properties. Nine formulations were prepared via freeze-thaw gelation and homogenization. They were analyzed for pH, viscosity, particle size, and zeta potential. The optimized formulation was further assessed through spreadability, Texture Profile Analysis (TPA), rheological tests, and in vitro occlusion studies.

All formulations showed skin-compatible pH and viscosity. Higher PVA increased viscosity and network strength, while olive oil influenced droplet size and viscosity. The optimized formulation (4 % PVA, 20 % olive oil) exhibited favorable rheology, texture, and spreadability. Occlusion studies showed a moderate occlusion factor of 62.69 ± 7.95 %, lower than petrolatum (89.26 ± 3.19 %) but higher than control (0 %), indicating formation of a thin semi-occlusive film that reduced transepidermal water loss and promoted hydration.

Surfactant-free emulgels using PVA can be successfully formulated. The moderate occlusion effect highlights their potential in dermal and cosmetic applications as biocompatible, stable, and patient-friendly systems.