Australia's first cold-process single-vessel co-formulation technique using marine bio-spicules to achieve 33–91× transdermal delivery of heat-sensitive actives. Zero prior art worldwide.
In vitro porcine skin, FD-10 (10 kDa)
Across dermis vs. passive control
BALB/c mice vs. passive control
Superior to microneedling control
Full cold-process — ambient temp
The One Pot Process (OPP) Method is a patent-pending cold-process, single-vessel co-formulation technique that uses marine bio-spicules from Haliclona sp. (oxea-type, 100–400 µm) as physical penetration-enhancement vehicles for heat-sensitive cosmetic actives.
Unlike conventional emulsification — which requires a separate heating phase at 70–75°C that denatures peptides, oxidises vitamin C, kills probiotics and destroys enzymatic actives — the OPP Method combines all ingredients, including the bio-spicules and the target actives, in a single vessel at ambient temperature.
Upon topical application, the needle-like silica spicules (∼120 µm length, ∼7 µm diameter) mechanically create transient microchannels in the stratum corneum via oscillatory motion, enabling direct sub-epidermal access for co-formulated actives. Skin disruption is self-limiting and recovers fully, as confirmed by transepidermal water loss (TEWL) studies in guinea pig skin in vivo.
Sustainably sourced Haliclona sp. marine sponge spicules are processed to achieve oxea-type geometry (∼120 µm length, ∼7 µm diameter). Size and purity are verified; purity of ≥90% is required for topical-grade application. The siliceous oxea structure — sharp-edged, rod-shaped — is the physical key to the delivery mechanism.
All ingredients — carrier base, actives, emulsifiers and spicules — are combined in a single vessel at ambient temperature using our AN.GNI AE300L-H rotor-stator homogeniser. No heating phase is required or permitted. Peptides, vitamin C derivatives, probiotics and enzymatic actives remain completely intact throughout manufacture — a fundamental impossibility in conventional hot-process emulsification.
Each batch is tested for pH, viscosity, spicule distribution uniformity, microbial limits, and active stability per GMP batch manufacturing record (BMR) protocols. Only batches meeting all specifications are released. Certificate of Analysis (CoA) issued per batch.
On skin application (massage or device-assisted), spicule oscillation physically creates transient microchannels in the stratum corneum via micro-puncture. No needles, no pain, no visible disruption. The mechanical action is self-limiting — skin barrier fully recovers, confirmed by TEWL measurement returning to baseline.
Spicules retained in skin for up to 72 hours act as sustained-release depots for co-formulated actives. Peer-reviewed data (Zhang et al., 2017) demonstrates 62× dermis accumulation of 10 kDa molecules vs. passive control — far exceeding what any surface-applied cream or serum can achieve through diffusion alone.
Standard emulsification at 70–75°C destroys the most clinically efficacious skincare actives. The OPP Method eliminates this constraint entirely. Every active below is now formulation-stable, activity-preserved, and deliverable transdermally at therapeutic concentrations.
Biotinoyl tripeptide-1 + red clover extract. Heat-labile at >45°C. OPP delivers intact to hair follicle dermis for DHT inhibition and follicle anchoring. Used in GS-002-A at 6.0%.
Palmitoyl tripeptide-1 + palmitoyl tetrapeptide-7. Collagen and elastin signalling peptide degraded above 50°C. OPP cold-process preserves full activity. Used in GS-002-A at 5.0%.
Biomimetic copper tripeptide. Thermally unstable complex. OPP cold-process enables full copper tripeptide delivery into dermis for wound repair signalling.
Sodium Ascorbyl Phosphate — the most stable Vitamin C derivative. Still oxidation-sensitive at elevated temperatures. Cold-process ensures zero oxidative loss from manufacture. Used in GS-004 at 3%.
Magnesium Ascorbyl Phosphate. Stable in cold-process but undergoes accelerated degradation above 40°C. OPP enables MAP at higher concentrations than hot-process competitors can achieve.
Though relatively stable, high-dose niacinamide benefits from cold-process preservation of co-formulated peptides. OPP achieves sub-epidermal delivery of niacinamide at concentrations not achievable by passive diffusion. Used in GS-003.
Probiotic-derived ferment lysate. Microbiome-active ingredient completely heat-inactivated above 37°C — impossible to include in any hot-process formulation. Cold-process preserves full postbiotic activity.
Plant-based retinol alternative that undergoes photo- and thermo-oxidation above 40°C. Cold-process manufacture preserves 100% of activity; OPP spicule delivery achieves retinoid-comparable epidermal depth.
Marine-derived carotenoid antioxidant — 6,000× stronger than Vitamin C but highly heat-labile. Cold-process is non-negotiable for any formulation making astaxanthin claims. OPP delivers it transdermally.
Stilbenoid antioxidant with proven anti-inflammatory and anti-aging activity. Degrades rapidly above 45°C. Cold-process OPP enables resveratrol concentrations that deliver measurable epidermal effect.
Enzymatic antioxidant denatured immediately above 40°C in conventional manufacturing. Cold-process OPP is the only way to include active SOD in a finished cosmetic product with delivery efficacy.
Epidermal growth factor and insulin-like growth factor analogues. Protein-based molecules denatured by heat and incapable of passive transdermal penetration. OPP solves both constraints simultaneously.
At standard emulsification temperature (70–75°C) vs. OPP cold-process (ambient ~22°C).
| Active Ingredient | Conventional (70–75°C) | OPP Cold-Process | OPP Transdermal Delivery |
|---|---|---|---|
| Signal Peptides (Capixyl, Matrixyl) | ❌ Denatured above 45–50°C | ✓ 100% intact | ✓ Sub-epidermal delivery |
| SAP / MAP Vitamin C | ⚠ Oxidation accelerated, degraded | ✓ Zero oxidative loss | ✓ Transdermal brightening |
| Bifida Ferment Lysate | ❌ Heat-inactivated above 37°C | ✓ Full postbiotic activity | ✓ Microbiome delivery |
| Bakuchiol | ⚠ Photo/thermo-oxidised above 40°C | ✓ 100% activity preserved | ✓ Retinoid-depth delivery |
| Astaxanthin | ❌ Rapidly degraded above 40°C | ✓ Carotenoid stability maintained | ✓ Antioxidant transdermal |
| Superoxide Dismutase (SOD) | ❌ Immediately denatured above 40°C | ✓ Full enzymatic activity | ✓ Enzyme-active delivery |
| EGF / IGF Mimetics | ❌ Protein structure destroyed | ✓ Tertiary structure preserved | ✓ Growth factor penetration |
| Niacinamide 10%+ | ⚠ Stable but co-actives degraded | ✓ All co-actives preserved | ✓ Sub-epidermal niacin delivery |
The OPP Method is protected by provisional patent application AU 2026901796, filed 5 March 2026 via IP Australia. Voluntary amendments were filed comprising 19 Statement of Proposed Amendments (SOPA) items and 11 restructured claims across 4 formal documents: Cover Letter, Clean Amended Specification, Marked-Up Specification, and SOPA.
A global prior art search across AU, US, EP, CN, KR and WO jurisdictions confirmed zero prior art — validating the cold-process bio-spicule co-formulation method as a genuinely novel invention with no existing patent landscape conflicts.
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