Sun block testing strategies included using right before getting in an outdoor pool, using right before getting in the car to go swimming, using after swimming 10 minutes and with wet skin, and occasionally remembering to re-apply after 2 or 3 hours. Some testers swam with sunscreen on for 1-4 hours. Other testers sat in the shade or stood by the pool for 1 to 3 hours. Generally, these products did not cover well on wet skin. Most have a faintly white color which will release onto the black car interior. Sun burns mostly resulted from not applying sunscreen to an area. There were very few sun burns after using sunscreen, even though it was rarely reapplied.
Sun block sprays were rejected because they were costly and wasteful, and they made testers cough.
Products were always chosen with an eye toward a higher SPF, and ingredients that protect against UVA rays (titanium dioxide, zinc oxide, avobenzone).
Products did well when they smoothed on skin easily, were easy to use on all exposed skin, didn't hurt the eyes, didn't feel strange, didn't smell horrible, and were easy to put on by younger testers. Keep in mind that a lot of products will hurt the eyes if they've been opened for a while. Once last summer's bottle has been opened, it may hurt the eyes next summer.
The best sun screens we tried last summer were (drumroll, please):
No-Ad, big orange bottle, sport lotion with a claim to water and sweat resistance. This lotion is currently replaced by their big blue bottle, which has a higher SPF. Key ingredient protecting against UVA rays: Avobenzone. I know this ingredient has been associated with an increase in free radicals, but this product smoothes on easily and stays on a long time. It didn't hurt anyone's eyes, and it is pretty cheap.
Close second: Banana Boat lotion in the big orange bottle. Another sport product that is supposed to be water and sweat resistant. Key ingredient is also avobenzone. This works just as well as No-Ad, but it is more expensive.
Best face sun screen for the extra-sensitive person: Ocean Potion's Face 45 SPF Potion. Key ingredient: zinc oxide. This cream is easy to put on and provides good coverage. It was initially rejected in favor of a stick formula, until the tester concluded that the sun block sticks didn't go on the skin as well. This cream did not hurt the eyes. The container is Recycle #7, so it may not be recyclable.
Second place finisher in the face sun block category: Banana Boat's face sun block sticks. These were easily applied and had a clear finish. Younger testers can put this on by themselves, with just a check from an older person for coverage. Key ingredient: I don't remember, probably avobenzone. Container not recyclable.
The losers?
Neutrogena Pure & Free Baby. This sun block stick probably works fine, but it has a white finish when it is applied, which some testers hated. I have two of these sticks left. I should probably just toss them because nobody will want to use them.
Aveeno Baby Natural Protection Mineral Block SPF 30. This lotion works pretty well, but it has a slightly gritty texture. You will be disappointed if you use this as a hand lotion. It is only slightly irritating to the eyes. Key ingredient: titanium dioxide. This product does not come in a recyclable container and it is a moderate to expensive drugstore product.
Biggest loser: Coppertone Water Babies Pure & Simple SPF 50. I had high hopes for this product, but when it is applied the lotion tends to stick to where it is first applied so it is hard to use quickly. It has a gritty feel, so don't use it as a hand lotion. Key ingredient: zinc oxide. Waterproof.
Note for next year: find a lotion that is inexpensive, does not contain avobenzone, and that is not irritating.
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