Acne is a multifactorial skin disease of the pilosebaceous unit. It is a complex inflammatory condition, in which one of the contributing factors is infection by Propionibacterium acnes, which plays a central role in its pathogenesis. Lime peel essential oil is rich in limonene (approximately 32%), which is known for its potent antibacterial activity. This study aims to evaluate the interactive effects of surfactant and co-surfactant concentrations on key physicochemical parameters—namely pH and percentage transmittance- while also identifying the optimal formulation, as well as assessing its physical stability and antibacterial performance. Using a factorial experimental design, Tween 80 (20–25%) and propylene glycol (15–20%) demonstrated interactive effects on the measured responses. Higher concentrations of Tween 80 and propylene glycol resulted in increased pH and percentage transmittance of the toner. Among the variables, Tween 80 was found to be the most influential factor affecting the responses. The optimized toner formulation consisted of 25% Tween 80 and 20% propylene glycol. Verification of the optimal formula using a one-sample t-test showed no significant difference between the predicted values (obtained from Design-Expert) and the experimental results for pH and percentage transmittance, as indicated by a Sig. (2-tailed) value of > 0.05. These results indicate excellent clarity and an ideal pH profile; however, a decrease in pH was observed after 8 weeks of storage. In addition, the incorporation of 15% lime peel essential oil exhibited antibacterial activity, producing an inhibition zone of 21.1 mm against P. acnes.
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