I still remember the trip where it all clicked. We were standing in airport security, bags on the conveyor belt, when a TSA agent pulled my daughter’s liquid sunscreen from her carry-on. I’d completely forgotten about the 3.4-ounce rule. He tossed it into that bin of half-used shampoos and confiscated perfumes, and just like that, our sunscreen for the trip was gone.
That moment stuck with me. It wasn’t just inconvenient; it was the realization that something as simple as staying protected from the sun shouldn’t be this hard when you travel. This became one of the driving forces behind creating Brush On Block’s travel-friendly sun protection system, products designed for real life, including the chaos of airport security lines. After years of wrestling with liquid size sunscreen limitations and travel regulations, I designed our products specifically to solve these challenges. Here's how to pack smart, stay protected, and never lose another sunscreen bottle to airport security.
Why Travel Shouldn’t Mean Compromising on Sun Protection
Whether you’re headed to the beach, exploring Europe, or packing for a work trip, sunscreen shouldn’t be a source of stress. Yet for most travelers, it is. Let's be honest about liquid sunscreen and travel. The TSA’s 3-1-1 rule (3.4 ounces or less, all in one quart-sized bag) creates immediate problems. Most liquid sunscreens are 5–8 ounces, so you’re forced to check a bag, transfer product to smaller containers, or buy sunscreen at your destination and hope it's reef-safe if you're heading somewhere tropical.
And then there’s the spill factor. I’ve lost count of how many times I’ve opened a suitcase to find sunscreen exploded all over my clothes. Even supposedly secure bottles can open under pressure changes during flights, creating messes that ruin vacations before they start.
Reapplication is another challenge most travelers don’t talk about. You need protection throughout your travel day — at the airport, during the flight (UV rays penetrate airplane windows), and as soon as you land. But try pulling out a liquid sunscreen in an airplane bathroom or at your gate without making a mess. It’s awkward, inconvenient, and most people just skip it.
The truth is, traditional sunscreens weren’t designed for how we actually live or travel. That’s what I wanted to change.
How We Engineered Truly Spill-Proof, TSA-Friendly Protection
When I set out to design a powder sunscreen that truly worked for travel, I knew the container design was just as important as the formula. A lot of powder sunscreens look similar at first glance. But here’s the difference: Brush On Block’s powder container has proprietary, spill-proof engineering we developed exclusively for our products. The goal wasn’t only to create a great product, it was to eliminate every point of friction that makes sunscreen a hassle.
The standard powder containers used by many brands continue to flow when not in use, and can open unexpectedly during travel. Pressure changes during flights, jostling in luggage, or even just the normal wear of daily use can cause those containers to pop open, spilling powder throughout your bag. I designed our container with a specialized locking mechanism that prevents powder from flowing when not in use or accidentally opening, even when your bag gets thrown around by baggage handlers or crushed under an airplane seat.
I’ve personally tested these containers through hundreds of flights. I’ve even had customers tell me their Brush On Block powder survived falls from hotel balconies or a full cycle in the washing machine (not recommended, but impressive!). That’s not luck, it's design. The security comes from intentional engineering.
The self-contained brush adds another layer of travel convenience. Because the brush lives inside the container, it stays clean and ready to use. No loose powder, no mess, no fumbling with separate applicators. Just reliable application that works anywhere, from airplane bathrooms to beach chairs.
The Complete TSA-Compliant Travel Protection System
If you’ve ever lost sunscreen to TSA, here’s the good news: Brush On Block products are designed for travel and all but our sprays are TSA-compliant (our 6 oz. spray-on mineral sunscreen lotions exceed the 3.4 oz. restriction).
Our Sheer Genius SPF 50 Mineral Sunscreen + Moisture provides your foundation protection in a compact, TSA-compliant container. At just over an ounce, it sails through security while delivering broad-spectrum SPF 50 protection with hydrating benefits.
Our Brush On Block SPF 30 and SPF 50 Mineral Powder Sunscreens are the real travel game-changers. The spill-proof container means you can toss them into your purse, backpack, or carry-on without a second thought. The built-in brush makes application and reapplication effortless anywhere: airplane bathrooms, beach lounge chairs, hiking trails or restaurant patios. No mess, no mirror required, no excuses.
And don’t forget your lips. Most travelers do, but they’re one of the first places to burn. Our compact Sun Shine SPF 30 Protective Lip Oil fits in any pocket or bag for frequent reapplication throughout your travels, and keeps your lips hydrated and protected. Unlike traditional lip balms that can melt in tropical heat, our lip oil maintains its protective properties in any climate.
Navigating International Travel and Reef-Safe Compliance
If your travels take you abroad, you already know sunscreen rules vary. Many destinations including Hawaii, Palau, Mexico’s coastal regions, and the U.S. Virgin Islands have banned certain chemical sunscreen ingredients that harm coral reefs. It’s easy to land in a tropical destination only to discover your sunscreen isn’t allowed.
Our complete mineral-based formulation solves this challenge. Zinc oxide and titanium dioxide, the active ingredients in all Brush On Block products, are reef-safe and compliant with international environmental regulations. That means you can travel anywhere with confidence that your SPF is safe for you and the planet.
European destinations present different considerations. Many European countries use PA rating systems alongside SPF ratings for UVA protection measurement. Our broad-spectrum formulations have been tested to international standards and provide comprehensive UVA and UVB protection, whether you're exploring Mediterranean beaches or Nordic fjords.
Packing Strategy: What Goes Where
After years of travel and product testing, here’s a packing strategy that works every time for travel sun protection.
Carry-On Essentials: Pack your SPF 30 or SPF 50 Mineral Powder Sunscreen in an easily accessible pocket. Thanks to the spill-proof container design, you can store it anywhere without worrying about powder explosions. Reapply during your flight (UV exposure increases at altitude), and having it readily available encourages consistent use. The SPF 30 Lip Oil should stay in your personal item for frequent access throughout your travel day.
Checked Luggage Strategy: Your Sheer Genius SPF 50 is great for application first thing in the morning, and still meets TSA size limits, so you can carry it on or check it.
Day Bag Organization: Once you arrive, your daily exploration bag should contain your powder sunscreen for easy reapplication and lip oil for constant lip protection. The compact size of both products means they fit in the smallest purses or daypack pockets with no excuses for skipping reapplication.
Real Travel Scenarios: Protection That Fits into Your Travel Schedule
Morning Routine in Hotel Bathrooms: Start with Sheer Genius SPF 50 as your moisturizer and sun protection base. It absorbs quickly, won't leave greasy residue on hotel towels, and you're protected before heading out for breakfast.
Beach Days: Toss your powder sunscreen in your beach bag for reapplication every two hours. The spill-proof container means no sandy mess, and the brush applicator works perfectly for on-the-go coverage without the white cast that some mineral sunscreens create. The lip oil is perfect for lip hydration and protection and frequent reapplication between swims.
City Exploring: When you’re sightseeing, reapply your powder sunscreen while waiting in museum lines, sitting at outdoor cafés, or walking in the park. It’s quick, invisible, and makeup-friendly.
Active Adventures: Hiking, biking, or water sports demand reliable sun protection that stays put. Our water-resistant powder formulations maintain effectiveness through sweat and splashes, with easy reapplication that doesn't interrupt your activities.
The Cost-Benefit Analysis of Travel-Friendly Protection
There’s a practical side to this too. Our powder sunscreens offer superior value for frequent travelers. The concentrated formulations last longer than liquid sunscreens where you're essentially carrying water weight. A single powder sunscreen container provides months of daily use, making the cost per application remarkably low.
And consider the hidden costs of inadequate sun protection while traveling: ruined vacation photos due to sunburn, medical treatment for severe burns in unfamiliar healthcare systems, and long-term skin damage that compounds with each unprotected trip. Investing in reliable, portable sun protection protects both your immediate trip and your long-term skin health.
If you want sun protection to become automatic, start before your trip. Get familiar with your products, decide where they’ll live in your bag, and make reapplication second nature. For me, the brush always lives in my carry-on’s front pocket, and the lip oil stays zipped in my purse. I don’t have to think about it anymore, it’s just part of how I travel.
Your skin doesn’t take a vacation from UV exposure — but with the right products, protection doesn’t have to slow you down. So pack light, travel easy, and remember: great adventures deserve great protection. Because travel should broaden your horizons, not damage your skin.
Making Sun Protection a Travel Habit, Not a Travel Hassle
After all these years, what I’ve learned is simple: the best travel sunscreen is the one you’ll actually use. When sun protection feels easy, it becomes a habit not a hassle. That’s why I designed these products the way I did: portable, mess-free, and reliable enough to keep up with real life. I've watched thousands of customers turn sun protection into a habit because the process became so simple.
If you want sun protection to become automatic, start before your trip. Get familiar with your products, decide where they’ll live in your bag, and make reapplication second nature. For me, the brush always lives in my carry-on’s front pocket, and the lip oil stays zipped in my purse. I don’t have to think about it anymore, it’s just part of how I travel.
Your skin doesn't take vacations from sun damage, even when you're on vacation. But with the right products, protection doesn’t have to slow you down. With TSA-compliant, spill-proof, genuinely portable sun protection, there's no excuse for skipping reapplication or arriving at destinations unprotected. Pack smart, protect consistently, and enjoy every adventure with confidence that your sun protection travels as well as you do.
