The increasing demand for eco-friendly and dermatologically a safe cosmetic formulation has encouraged the exploration of plant-derived surfactants as sustainable alternatives to synthetic cleansing agents. The present study aimed to develop and optimize a mild herbal shampoo incorporating Sapindus mukorossi saponins as a natural surfactant system, along with Phyllanthus emblica, Aloe vera, and Azadirachta indica extracts for antioxidant, conditioning, and antimicrobial benefits. Twenty-five trial formulations were prepared using varying concentrations of natural surfactant (5–15% w/w) and evaluated for physicochemical and performance parameters. Optimization was performed based on foam stability, viscosity, and pH compatibility using statistical analysis (one-way ANOVA, p < 0.05).

Among the formulations, F8–F14 exhibited optimal characteristics, with pH ranging from 5.7–5.9, viscosity between 3100–3400 cP, foam stability above 40%, and acceptable wetting time (<60 s). The optimized formulation demonstrated effective detergency with minimal dirt redeposition and maintained scalp-compatible pH.