E-Liquid Manufacturing Process
E-liquid and e-cigarette products are highly regulated products due to TPD laws. Here in the UK, every bottle of e-liquid has to follow a strict manufacturing process to ensure that the finished product is safe.
We’ve created a guide of the manufacturing process, so you know exactly how your e-liquid is made.
Sourcing Ingredients:
E-liquids are made from raw ingredients, the ingredients used are not kept a secret because you can make your own e-liquids in the comfort of your own home. The exact recipes of these e-liquids are often kept top-secret to prevent competitors and consumers from replicating some of the best-selling flavours.
- Base Ingredients – Every e-liquid is made of 2 base ingredients: vegetable glycerin (VG) and propylene glycol (PG). The ratio of these ingredients can change depending on the desired outcome however the most common blends are 50/50 and 70/30.
- Flavour Concentrates – Concentrates are added to create flavour, this is when it gets secretive. A lot of the concentrates from top brands such as Vampire Vape are available to buy as flavour concentrates so you can make your own.
- Nicotine – Nicotine is added in some e-liquids but not always. Nicotine content in the UK can only be sold between 0 and 20mg/ml.
Production
Production of e-liquid in the UK has to be carried out in a lab or a clean room. A clean room is a controlled environment that makes it clean and safe to produce e-liquids without risk of contamination.
- Procurement: All ingredients that go into e-liquids have to adhere to strict TPD regulations. Most ingredients are sourced in the UK, EU or US.
- Weighing: The ingredients are then measured or weighed depending on their recipe and required quantities. Staff in labs and clean rooms must wear PPE to prevent contamination and to keep workers safe.
- Mixing – The ingredients are then mixed together by hand or by machine.
- Filling – Once mixed, the ingredients are poured into individual e-liquid bottles. Larger companies have bespoke machinery for this process.
- Labelling – Every bottle is labelled with the brand, e-liquid name and a list of compliances and regulations. Most e-liquid bottles will also have full batch traceability which means that if you ever have a problem, the company will be able to source the problem through their production line.
- Packaging – Once bottled up, the e-liquid is then packed and checked to ensure that it reaches the same standard. These are then packed in boxes and stored ready to be shipped out around the world.
- Quality Control – E-liquids have to go through testing to ensure that the flavours and nicotine levels are correct. This holds all e-liquids to the same high standard.
All e-liquids sold in the UK have to be TPD compliant which is why the process is so rigorous and strict.
