Author Archives: Hannah Rubery

Xyfil Ltd   →  Articles by: Hannah Rubery
Author Hannah Rubery Categories E-Liquid, Regulations Posted on

The Countdown to October 2026: Understanding the UK’s New Vaping Tax

The UK vaping industry is on the brink of its most significant regulatory change in years. While the market has grown and evolved rapidly, a major shift is coming that will impact every brand, manufacturer, importer, and consumer: the introduction of the Vaping Products Duty (VPD).

This isn't just about a few pennies being added to the price tag; it's a fundamental change to the operational and financial landscape of UK vaping. At Xyfil, we believe preparedness is key. We’re here to break down exactly what the new vape tax UK will mean for your business and how we can help you navigate this transition smoothly.

The Vaping Products Duty (VPD) Explained

The UK government has officially confirmed the introduction of a new excise duty on vaping products. Here are the core facts you need to know about the upcoming legislation:

The Key Dates

  • Registration Opens: 1 April 2026. Businesses that manufacture or import vaping liquids will need to register with HMRC to comply with the new duty requirements.
  • Operative Date: 1 October 2026. The Vaping Products Duty will officially take effect, meaning all products released for consumption on or after this date will be subject to the new tax.

The Scope and the Rate

The new duty applies to all vaping liquid containing nicotine that is produced in, or imported into, the United Kingdom.

Crucially, the government has adopted a simplified, flat-rate structure regardless of nicotine content. This means that 0mg/nicotine-free and nicotine containing E-liquids will be charged £2.20 per 10ml.

This fixed amount is arguably the most impactful detail. Unlike previous proposals that considered tiered rates based on nicotine strength, this new flat rate applies regardless of how much nicotine is in the liquid.

Why the New Vape Tax UK is Being Introduced

The government's policy objective is two-fold:

  1. Reduce Youth Uptake: To make vaping products less affordable and appealing to young people and non-smokers.
  2. Maintain the Incentive to Switch: To ensure that the financial incentive for adult smokers to switch to less harmful alternatives remains. To achieve this, the government has announced a commensurate increase in tobacco duty to take effect simultaneously.

Beyond the Price Tag – The Commercial and Consumer Impact

While the £2.20 per 10ml rate may seem straightforward, its ramifications are deep, affecting financial strategies, logistics, and consumer behaviour.

Impact on Brands, Manufacturers, and Importers

For the businesses that make or move these products, the change is an operational challenge:

  • Financial & Administrative Burden: Businesses will face one-off costs related to familiarisation, registration, and staff training. Ongoing costs will include submitting monthly returns and managing the duty calculation.
  • New Regulatory Compliance: Brands are now part of the existing excise regime, meaning stricter controls and HMRC oversight.
  • The Vaping Duty Stamps (VDS) Scheme: Alongside the duty itself, a new Vaping Duty Stamps scheme is being introduced. This requires product packaging to incorporate a physical or digital stamp to prove compliance, adding a complex layer of security and logistics to production lines.

Impact on the Consumer

An estimated 5.1 million individuals who vape will see an increase in the price of their products.

  • The Price Shock: Products will undoubtedly become more expensive. A standard 10ml nicotine-containing e-liquid, for instance, will see a £2.20 duty added before VAT, which is a significant increase.
  • Disproportionate Cost: Due to the flat rate, low-nicotine products (often used by those transitioning from cigarettes) will see a disproportionately high price increase relative to their nicotine content.
  • Shifts in Strategy: Brands must quickly review their pricing. Will you absorb a portion of the duty, or pass the full cost onto the consumer? This decision will be vital in maintaining market share and competitiveness.

How Xyfil Helps Brands Navigate the New Vape Tax UK

The good news is that Xyfil is already planning and developing solutions to help your brand not only comply with the VPD but to thrive in the new market. We offer a three-pillar strategy for duty readiness:

1. Compliance & Regulatory Support

We remove the administrative burden so you can focus on your product.

  • Duty Registration Readiness: We provide clarity on the registration process opening in April 2026, ensuring you have all the necessary information and documentation prepared for submission.
  • VDS Implementation Guidance: The Vaping Duty Stamps scheme requires precision. We advise on how to seamlessly integrate the necessary packaging changes and security protocols into your production workflow.
  • Supply Chain Audit: We help you identify the precise point in your supply chain where the duty will be levied (upon production or import), allowing you to optimize your logistics for duty suspense and storage.

2. Formulation & Cost Optimization

Since the UK vape tax is based on volume (£2.20 per 10ml), smart formulation and packaging strategy will be essential.

  • Volume-Based Pricing Review: We consult on adjusting TPD-compliant volumes and packaging formats. For instance, brands might explore optimized shortfills or concentrate options to manage consumer cost expectations.
  • Strategic Nicotine Review: We analyse your existing nicotine salt and freebase formulations to determine if strategic adjustments can help maintain consumer value post-duty without sacrificing the quality or satisfaction of your product.
  • Ingredient & Flavour Costing: Our experts conduct detailed analyses of your current costs, helping you mitigate rising overheads and preserve necessary profit margins amid the tax increases.

3. Ready-Made, Compliant Solutions

For brands that need to pivot quickly or want to avoid the new operational complexity altogether, Xyfil offers fully compliant solutions. We provide high-quality, tax-ready e-liquids, concentrates, and components, allowing you to streamline your product launch and maintain focus on sales and marketing, not regulatory headaches.

Conclusion: The Time to Act is Now

October 1st, 2026, might sound far away, but the preparatory work—including internal audits, supply chain optimization, and, most crucially, packaging revisions for the Vaping Duty Stamps—needs to start immediately.

The Vaping Products Duty is set to redefine the UK market, but it doesn't have to break your business. By partnering with an expert like Xyfil, you can turn this regulatory challenge into an opportunity to solidify compliance, optimize your product strategy, and future-proof your brand.

Don't wait until 2026. Let our expertise in compliance and formulation ensure your brand is not only ready for the new vape tax uk but positioned for sustained success.

Contact Xyfil today to schedule your duty-readiness consultation.

Author Hannah Rubery Categories E-Liquid, Manufacturing Posted on

Why You Should Choose a UK-Based E-Liquid Manufacturer

In the high-stakes world of e-liquid brands, your choice of manufacturing partner dictates not only your product's cost but, more importantly, its safety, quality, and legal compliance. While overseas options often tempt with lower unit costs, savvy brand owners understand that this perceived saving can swiftly turn into catastrophic financial and reputational loss.

Choosing a trusted UK-based E-liquid manufacturer like Xyfil is an investment in consumer trust and regulatory certainty. Our commitment to stringent domestic standards ensures quality from the ground up.

This post breaks down the three crucial advantages UK manufacturing offers that unregulated overseas options simply cannot guarantee.

The Critical Difference: Non-Negotiable Regulatory Compliance

Compliance is the foundation of any successful e-liquid brand operating in the UK and European markets. The regulatory environment here is one of the most rigorously enforced globally, providing consumers and businesses with unmatched safeguards.

Strict UK/EU TPD/TRPR Framework

The core of our domestic regulatory superiority lies in the Tobacco and Related Products Regulations(TRPR), which implements the European Union's Tobacco Products Directive (TPD). These are not suggestions; they are strict laws that govern every aspect of E-liquid manufacture and sale:

  • Bottle Size and Strength: Nicotine-containing E-liquids are limited to a maximum bottle size of 10ml and a nicotine strength of 20mg/ml.
  • Banned Ingredients: The regulations specifically prohibit the inclusion of substances like Diacetyl, Caffeine, Taurine, and certain colourings due to associated health risks.
  • Mandatory Packaging: All products must feature child-resistant and tamper-evident packaging, along with standardised health warnings.

MHRA Notification and Testing: Safety First

Before any product can legally be sold in the UK, the manufacturer must complete the demanding MHRA (Medicines and Healthcare products Regulatory Agency) notification process.

This step is crucial and time-consuming, requiring the manufacturer to submit detailed toxicological and emissions testing results. This laboratory analysis proves that the e-liquid, when vaporised, is free from unsafe levels of carbonyl compounds and other harmful emissions.

  • Overseas Risk: Overseas manufacturers frequently either ignore these requirements entirely or perform superficial, non-certified checks, leaving the importer (your brand) exposed. Products failing to appear on the MHRA register are illegal and risk being seized and banned from the UK market.

Legal Liability and Guaranteed Traceability

When you partner with a UK manufacturer, they assume the full legal responsibility for compliance within the UK and European market. They are the point of contact for regulators and inspectors.

  • Protect Your Brand: If you import from an unregulated overseas source, the legal liability often defaults to your importing brand.
  • Full Traceability: Regulatory compliance demands a chain of custody. Reputable UK partners provide batch code testing and full traceability, meaning every component, from raw nicotine to the final label, can be tracked back to its source and manufacturing stage—a mandatory feature of UK/TPD compliance that safeguards public health and your brand integrity.

Unrivalled Quality Control and Ingredient Sourcing

Beyond meeting minimum legal requirements, quality control separates market leaders from fly-by-night operations. UK-based manufacturing operates under a commitment to quality that is difficult to replicate cheaply overseas.

Pharmaceutical-Grade Ingredients: Purity Matters

The quality of raw materials is paramount. Leading UK E-liquid manufacturers only work with suppliers who can guarantee pharmaceutical-grade purity for essential ingredients:

  • UK Standard: High-purity Propylene Glycol (PG), Vegetable Glycerin (VG), and Nicotine.
  • Overseas Risk: Brands sourcing from less reputable locations risk using “industrial-grade” ingredients, which can contain harmful contaminants, impurities, or even unregulated nicotine sources (such as pesticide-grade nicotine), compromising both the vaping experience and consumer safety.

Certified Manufacturing Environments

Xyfil invests heavily in facilities that meet global gold standards for safe production. We don’t manufacture e-liquid in general factories; we produce it in environments specifically designed for pharmaceutical-grade products:

  • Certified Facilities: Look for ISO 9001 (Quality Management), GMP-compliant processes, and crucial ISO 7 Cleanroom environments.
  • Contamination Control: Using cleanrooms ensures that products are manufactured in a temperature- and pressure-controlled environment, free from environmental contaminants, cross-contamination between batches, and particulate matter.

Rigorous Internal Testing Protocols

Reputable UK manufacturers go above and beyond the required TPD tests. They employ internal, continuous quality control (QC) checks to ensure unparalleled consistency and safety:

  • Raw Material Vetting: Testing incoming PG, VG, and nicotine for purity before use.
  • Batch Analysis: Checking nicotine concentration consistency and verifying the VG/PG ratio for every single batch produced.
  • Organoleptic Testing: Employing expert analysis to ensure the aroma and taste profiles of the e-liquid are consistently identical to the standard reference sample, ensuring your customers receive the same great experience every time.

Supply Chain Security and Strategic Partnership

In today's unpredictable global market, a resilient supply chain is a strategic advantage. Working locally provides predictability and a level of partnership that is impossible to achieve when dealing with overseas options.

Seamless Communication and Local Access

When regulations change, or a product needs urgent modification, time is always critical.

  • Ease of Access: Dealing with a UK-based partner means avoiding frustrating time zone differences and language barriers. You benefit from immediate, clear communication and the ability to personally visit the manufacturing facility to oversee processes or consult on product development.
  • Customization: Local partners offer faster, more agile custom flavour development and packaging amendments—essential when regulations shift or market trends dictate a rapid change.

Faster Time-to-Market and Cost Predictability

The costs of global shipping have become volatile and unpredictable. Domestic sourcing eliminates many of these financial and logistical headaches:

  • Domestic manufacturing drastically reduces shipping times, removes costly and unpredictable customs duties and import tariffs, and simplifies logistics dramatically.
  • This translates to faster lead times, fewer out-of-stock events, and more predictable bottom-line costs.

Risk Management and Supply Resilience (The Xyfil Advantage)

A local, robust supply chain acts as a buffer against global disruption.

At Xyfil, we operate a preferential UK supply chain policy and maintain exhaustive risk management strategies for every component. We have established redundancy for critical raw materials, ensuring continuous production regardless of global trade disruptions. When global events (like the pandemic or shipping crises) interrupt international trade, UK-centric, robust supply chains mean your product supply remains uninterrupted.

Investing in Your Brand's Future

The choice between a UK-based e-liquid manufacturer and an overseas option isn't about choosing between cheap and expensive; it's about choosing between risk and assurance. Your brand's reputation and financial stability hinge on your ability to guarantee compliance, quality, and certainty to your customers.

Partner with Xyfil today to ensure your products meet the highest safety, quality, and regulatory standards, guaranteeing peace of mind and long-term success in the competitive e-liquid market.

Author Hannah Rubery Categories E-Liquid Posted on

Can AI Predict the Next Big Vape Flavour Trend?

The vaping world moves fast — sometimes faster than brands can keep up. One moment, classic fruits are dominating; the next, everyone wants icy mango or complex dessert blends. For brand owners trying to stay ahead of demand, predicting the next flavour trend can feel like trying to catch smoke.

But what if data could do the guessing for us? As artificial intelligence continues to evolve, AI-driven trend prediction is becoming increasingly influential across food, fragrance, and lifestyle sectors. Now, it’s beginning to shape how vape brands think about the future of flavour.

So, can AI really predict the next big vape trend? And more importantly — should you trust it?

1. The Challenge of Forecasting Flavour Trends

Traditionally, brands have relied on a mix of customer surveys, retailer feedback, sales reports, and social listening. These methods work, but they’re often reactive, highlighting trends after they’ve taken off.

By the time a new flavour hits the shelves, consumer interest may already be shifting.

AI offers an alternative: fast, scalable insights that detect early signals and help brands innovate ahead of the curve.

2. How AI Analyses Consumer Behaviour

AI can process millions of data points in seconds. Machine learning models analyse social conversations, search queries, product reviews, and even global buying behaviour to identify emerging trends.

This allows AI to detect:

  • keywords increasing in popularity
  • geographic differences in flavour preferences
  • patterns in consumer sentiment
  • seasonal behaviour shifts
  • demographic leanings

For example, AI might spot that searches for “botanical mint” are rising in the UK, while Southeast Asia shows early interest in creamy tropical beverages.

These are insights brands can act on long before traditional analytics catch up.

3. AI in Action: How Other Industries Use It

The power of AI trend forecasting is already proven across multiple sectors.

Food and beverage companies use AI to predict the next popular ingredients. Perfume houses rely on algorithms to anticipate emerging scent notes. Even major drink brands test AI-suggested flavours against consumer panels before release.

For vaping, this kind of predictive intelligence could highlight rising demand for:

  • nostalgic dessert flavours
  • exotic fruit blends
  • botanical or floral profiles
  • beverage-inspired options
  • hybrid categories (e.g., “creamy ice”)

AI gives brands a head start. It's not a guarantee, but a powerful advantage.

4. What This Means for Vape Brands

AI-supported trend forecasting can transform how vape brands approach product development:

Faster innovation cycles
Brands can respond to market shifts earlier and launch flavours at the peak of demand.

Better portfolio decisions
Instead of guessing which concepts might work, brands can prioritise flavours with demonstrated momentum.

Sharper marketing strategies
AI doesn’t just predict what consumers want, it reveals who wants it and why.

More targeted regional launches
Flavour popularity varies globally, and AI helps brands tailor releases to local tastes.

Data-driven decision-making leads to smarter investments, better-performing ranges, and deeper consumer loyalty.

5. Challenges and Ethical Considerations

While AI offers huge potential for flavour prediction, it comes with important challenges that brand owners should consider.

Data bias is a serious concern.

AI heavily depends on the platforms it analyses. TikTok trends may overrepresent younger users, while specialist forums might skew toward experienced vapers. If these imbalances aren’t accounted for, predictions can become distorted and misaligned with real demand.

Privacy and regulatory compliance must be respected.

With increasing scrutiny on how consumer data is used, brands must ensure AI tools follow strict privacy standards. Transparent, ethical data collection is essential to avoid compliance issues.

A risk of homogenisation.

If every brand uses similar AI tools trained on similar data, many companies may end up releasing very similar flavours. Instead of diversity, the market could become saturated with the same trending profiles — unless creativity remains central.

AI can misinterpret short-term spikes.

A flavour that goes viral one week doesn’t always translate into long-term demand. Without human analysis, brands may invest in concepts that don’t sustain interest.

AI should act as a strategic partner, not a replacement for industry expertise, compliance considerations, or creative oversight.

6. How Brands Can Use AI Without Losing Creativity

AI is most powerful when paired with human talent. The goal isn’t to replace creative development, but to enhance it.

Use AI as a compass, not a formula.

AI can highlight categories gaining traction, but your team decides how those insights translate into flavours that align with your brand identity.

Guide R&D with data — but let creativity take the lead.

AI might signal rising interest in creamy citrus flavours, but your flavourists determine whether that becomes a lemon chiffon, a key lime gelato, or a tangerine cream soda.

Test small batches to validate predictions.

Limited editions and regional releases help brands experiment safely while gathering real-world feedback.

Leverage sensory expertise.

Only human flavourists can refine mouthfeel, vapour density, and balance elements AI can't yet judge. Their experience is essential for turning AI insights into high-performing formulations.

Keep brand storytelling central.

Two brands may share similar AI insights, yet interpret them in completely different ways. Creativity, cultural insight, and brand personality must remain core drivers.

Brands that blend data with creativity outperform those that rely exclusively on one or the other.

7. The Future of AI in Flavour Development

We’re still at the beginning of AI’s impact on the vape industry, and its future potential is substantial.

AI-assisted formulation will become more common.

Algorithms will help chemists model how flavour compounds interact, predicting sweetness levels, volatility, aftertaste, and potential off-notes, reducing R&D time while improving precision.

AI will optimise flavours for different devices.

As coil and heating technologies evolve, AI could predict how formulations will behave in mesh coils, pod systems, or higher-wattage devices, tailoring recipes for optimal performance.

Long-term consumer behaviour forecasting.

AI may identify macro-trends such as a shift toward less sweetness, more natural profiles, or evolving preferences in cooling intensity.

Personalised vaping experiences.

Like personalised nutrition and skincare, AI might one day suggest flavour profiles based on individual preferences, behaviour, or location.

Brands that integrate AI early gain a competitive edge — not just in predicting trends, but in shaping them.

Conclusion: AI as a Partner, Not a Replacement

AI is an invaluable tool for forecasting emerging flavour trends, but it works best when used alongside human creativity, market understanding, and expert formulation.

It accelerates insight, reduces uncertainty, and helps brands make more confident decisions, but the artistry of flavour development still depends on people.

For vape brands aiming to stay ahead in 2025 and beyond, AI isn’t the future by itself — it’s a key part of it.

Author Hannah Rubery Categories E-Liquid, Manufacturing, Production Posted on

Best Practices for Consistent Flavour and Quality: E-liquid Manufacture

In the competitive world of e-liquid manufacturing, consistency is everything. For vapers, flavour is more than just a preference — it’s an expectation. They return to their favourite brand because they trust that every bottle will taste, feel, and perform exactly the same as the last.

For manufacturers, achieving that level of reliability requires precision at every stage of production. Even the smallest variation — a slightly different flavour strength, a marginally altered viscosity, or a subtle shift in colour — can undermine brand confidence.

Let’s explore what causes batch variation, how to prevent it, and how Xyfil ensures every product meets the highest standards of flavour and quality.

Understanding Batch Variation in E-Liquid Manufacturing

Batch variation refers to small differences between production runs of the same e-liquid — changes that might affect flavour, vapour production, or throat hit.

These variations can stem from a range of factors:

  • Ingredient inconsistencies (such as flavour concentrates or nicotine strength)
  • Environmental conditions like temperature and humidity
  • Equipment calibration that drifts over time
  • Human error during measurement or mixing

For consumers, even a subtle difference can feel noticeable. For brands, this can lead to product returns, compliance concerns, or reputational harm — making consistency not just desirable, but essential.

Precision Ingredient Management

Consistency starts with control. High-quality, traceable ingredients form the foundation of every reliable e-liquid.

At Xyfil, we work exclusively with trusted suppliers who meet strict purity standards for PG, VG, flavour concentrates, and nicotine. But quality sourcing is only the beginning — accurate measurement and controlled storage are equally vital.

Precise weighing systems, climate-controlled ingredient storage, and batch-coded traceability ensure every blend starts from a consistent base. That’s the first step toward flavour uniformity.

Standardising the Mixing Process

The mixing stage is where the magic happens — and where variation can easily creep in. To maintain uniformity, standardisation is key.

Every stage of the mixing process should be guided by detailed Standard Operating Procedures (SOPs) that define quantities, timings, and environmental conditions.

Automated blending systems help minimise human error and ensure ingredients are mixed evenly. Meanwhile, monitoring temperature and humidity helps maintain stability, ensuring that the same formulation produces the same result every time.

Equipment Calibration and Maintenance

Consistency also depends on the tools behind the process. Even the most advanced filling or blending machines can produce discrepancies if not properly calibrated.

Regular maintenance schedules and calibration logs are essential for ensuring equipment accuracy. At Xyfil, digital monitoring systems and automated calibration checks are part of our routine — ensuring every component of the production line performs exactly as intended.

When machinery performs predictably, the results follow suit.

Quality Control and Analytical Testing

Quality control is where consistency becomes measurable. Every batch should undergo rigorous testing before it reaches market — not just for compliance, but for flavour fidelity.

This includes checking:

  • Flavour profile consistency against reference samples
  • Nicotine strength and accuracy
  • Viscosity and colour uniformity
  • Vapour production performance

Beyond sensory testing, analytical tools such as Gas Chromatography-Mass Spectrometry (GC-MS) can verify the chemical consistency of flavour compounds. At Xyfil, these processes ensure every product that leaves our facility meets both regulatory and sensory expectations.

Data Tracking and Traceability

Every successful manufacturer knows that traceability is the backbone of quality assurance. From raw ingredients to final bottling, data tracking allows for full visibility of each batch’s journey.

Advanced batch tracking systems record ingredient sources, mixing data, and test results — making it possible to trace and identify even the smallest anomaly.

This not only supports quality control but also empowers proactive problem-solving. If trends begin to emerge, corrective measures can be implemented long before they affect a customer’s experience.

Staff Training and a Culture of Quality

Technology and process control are powerful, but people remain central to quality. Every team member involved in production must understand how their role impacts consistency.

Regular training, process audits, and a company-wide quality mindset ensure everyone works toward the same goal — delivering a flawless product every time. At Xyfil, this focus on people and process helps us maintain precision at scale.

How Xyfil Ensures Flavour and Quality Consistency

Consistency isn’t left to chance at Xyfil. Our integrated quality assurance systems are built into every stage of production — from ingredient sourcing to final packaging.

We combine:

  • Automated blending and filling technologies
  • Precision calibration and data tracking systems
  • In-house analytical testing
  • A robust quality management framework

The result? Every batch reflects the same commitment to flavour accuracy, smoothness, and reliability — ensuring your customers get exactly what they expect, every time.

Conclusion: Consistency Is a Competitive Advantage

In the vaping industry, consistency isn’t just a technical achievement — it’s a brand promise. Consumers reward reliability with loyalty, and brands that deliver uniform flavour and quality stand out in a competitive market.

By prioritising precision, process control, and testing, you’re not just reducing variation — you’re strengthening your brand’s identity and trustworthiness.

At Xyfil, we help our partners achieve this standard of excellence through advanced manufacturing, rigorous testing, and an unwavering focus on quality. Because when every bottle performs perfectly, your brand reputation grows stronger with every puff.

Author Hannah Rubery Categories E-Liquid, Manufacturing Posted on

How Mesh Coil Technology is Changing Flavour Formulation

The vape industry is constantly evolving, and technology is at the heart of this transformation. One of the most significant innovations in recent years is mesh coil technology. While coils might seem like a small component, they have a major impact on how e-liquids perform — and that, in turn, affects flavour formulation. For brand owners and product developers, understanding mesh coils is essential to creating products that delight consumers.

What Is Mesh Coil Technology?

Traditional vape coils use a single wire wrapped around a wick. Mesh coils, by contrast, replace the wire with a fine sheet or mesh of metal. This increases the surface area that comes into contact with the e-liquid, providing more uniform heating.

The result is:

  • Enhanced flavour delivery — e-liquids taste richer and more nuanced.
  • Smoother vapour — fewer hotspots lead to a more consistent experience.
  • Better coil longevity — even heating reduces burn-off and degradation.

For brands, this shift isn’t just technical — it changes the way flavours are experienced, opening up new possibilities in formulation.

Why Mesh Coils Change the Game for Flavour

Flavour is no longer just about the ingredients in the bottle. The delivery mechanism affects how the consumer experiences every note, from top-layer brightness to subtle undertones. Mesh coils allow formulators to:

  1. Enhance delicate flavours
    • Light, intricate flavours such as floral blends, tea-inspired profiles, or complex desserts come through more clearly.
  2. Balance stronger notes
    • Bold flavours like menthol or concentrated fruit don’t overwhelm the palate because heat distribution is even.
  3. Improve consistency across puffs
    • Each inhale delivers the same rich, full flavour, helping build customer loyalty.

This means brand owners can be more adventurous with flavour profiles. Recipes that may have been muted or harsh on traditional coils can now shine.

Implications for Product Development

Mesh coils don’t just improve existing flavours — they influence the formulation process itself. Brand owners developing new vape products should consider:

  • Viscosity adjustments
    • Mesh coils work best with e-liquids that balance VG and PG for smooth wicking and optimal heat transfer.
  • Flavour layering
    • Complex blends can now be expressed more accurately, enabling signature ranges that stand out on the shelf.
  • Nicotine delivery
    • Consistent heat distribution ensures smoother throat hits for nicotine salts while maintaining flavour integrity.

By aligning formulation with mesh coil performance, brands can launch products that are both satisfying and market-leading.

Consumer Expectations Are Evolving

Today’s vapers are more discerning than ever. They expect crisp, clean flavours that match the marketing description, a smooth, enjoyable vapour with no burnt notes, and consistency across devices and puffs.

Mesh coils make it easier to meet these expectations, which means e-liquids must be formulated with precision. Brands that ignore this shift risk underwhelming their audience, even if the flavour itself is high-quality.

How Xyfil Helps Brands Leverage Mesh Coil Technology

At Xyfil, we understand that innovation in coil technology demands innovation in formulation. Our team works with brand owners to:

  • Develop e-liquids optimised for mesh coils.
  • Balance VG/PG ratios and flavour compounds for maximum impact.
  • Test products across multiple devices to ensure consistency.
  • Translate technical advantages into flavours that resonate with consumers.

By considering mesh coil performance from the start, brands can ensure their new products deliver an exceptional vaping experience every time.

Conclusion

Mesh coil technology has transformed how flavours are delivered and perceived. For brand owners, it’s more than a hardware upgrade — it’s an opportunity to rethink formulation, push creative boundaries, and satisfy a more demanding consumer base.

By embracing mesh coil-friendly e-liquids and optimising formulation strategies, brands can create products that stand out in a crowded market and deliver the full flavour experience vapers crave.

Author Hannah Rubery Categories Compliance, Manufacturing Posted on

The Role of ISO Certification in E-Liquid Manufacturing

The e-liquid industry has grown tremendously over the past decade, evolving from a niche market into a global phenomenon. With this growth comes a heightened responsibility for manufacturers to ensure their products are not only enjoyable but also safe and reliable. At Xyfil, we take this responsibility seriously, and our ISO and GMP certifications reflect our dedication to quality, safety, and consistency in every product we create.

Understanding ISO Certification in E-Liquid Manufacturing

You might have heard of ISO certification in passing, but what does it really mean for e-liquid production? ISO, or the International Organization for Standardization, sets globally recognized standards that ensure businesses maintain consistent quality and operational efficiency. Specifically, ISO 9001:2015—the standard Xyfil adheres to—is all about streamlining processes, reducing errors, and making sure every product leaving the facility meets rigorous quality benchmarks.

For e-liquid manufacturers, this is more than a stamp of approval. ISO certification guarantees that every bottle produced is consistent in flavour, strength, and overall quality. It also boosts operational efficiency, helping reduce waste and maintain precise control over every step of the production process. Most importantly, it builds trust—with retailers, regulators, and consumers alike. When you see an ISO-certified e-liquid manufacturer, you know they’re serious about doing things right.

The Significance of GMP Certification in E-Liquid Production

While ISO focuses on quality management systems, GMP—or Good Manufacturing Practices—takes a more hands-on approach to product safety. GMP certification ensures that every aspect of production, from raw material sourcing to packaging, is carried out under strict hygiene and safety protocols.

At its core, GMP is about accountability. It requires detailed record-keeping, traceability, and rigorous quality checks at every stage. For consumers, this means that every puff is safe, reliable, and consistent with the brand’s standards. GMP compliance also ensures that manufacturers like Xyfil are meeting international health and safety requirements—a critical factor in today’s global market.

Xyfil’s Commitment to Excellence: ISO and GMP Certifications

At Xyfil, quality isn’t just a goal—it’s embedded in everything we do. Our ISO 9001:2015 certification demonstrates that our systems and processes are designed to consistently deliver top-tier products. From initial formulation to final packaging, every step is monitored and optimized to meet strict international standards.

Our GMP certification complements this by focusing on the safety and integrity of our production environment. Every batch of e-liquid is produced in a controlled, hygienic setting, ensuring that nothing compromises the product’s safety or quality.

By combining ISO and GMP standards, Xyfil offers clients and partners peace of mind. You can trust that our e-liquids are not only crafted with care but also meet rigorous global standards—making us a reliable partner for brands and retailers looking for safe, high-quality products.

Industry Trends and the Regulatory Landscape

The global e-liquid market is evolving fast, with regulations becoming increasingly stringent. Today, certifications like ISO and GMP are more than just optional—they’re essential for compliance and consumer confidence. Manufacturers who embrace these standards are better equipped to navigate complex regulatory environments, ensuring their products meet or exceed legal requirements.

At Xyfil, our certifications position us ahead of the curve. By maintaining high standards, we can adapt quickly to changing regulations while continuing to deliver consistent, safe, and enjoyable products to the market.

Conclusion

Quality, safety, and consistency are non-negotiable in e-liquid manufacturing. ISO and GMP certifications aren’t just badges—they’re commitments to excellence that consumers, partners, and regulators can rely on. At Xyfil, these certifications are a reflection of our dedication to producing safe, reliable, and high-quality e-liquids every time.

When you choose to partner with Xyfil, you’re choosing a manufacturer that values precision, safety, and continuous improvement. Reach out to us today to learn more about our ISO and GMP-certified manufacturing services and discover how we can help bring your e-liquid products to market with confidence.

Author Hannah Rubery Categories E-Liquid, Manufacturing Posted on

The Science of Mouthfeel in E-Liquid Formulation

When we think about what makes a great e-liquid, flavour usually takes centre stage. But ask any experienced vaper and they’ll tell you: it’s not just about taste. The feel of the vapour — the texture, smoothness, and sensation as it hits the throat — is just as important.

This is what’s known as mouthfeel, and it plays a huge role in whether customers come back for more. For brand owners, understanding the science behind mouthfeel is essential to creating products that satisfy not just the palate but the full vaping experience.

What Is Mouthfeel in Vaping?

In food and drink, mouthfeel refers to the texture and body of what we consume. In vaping, it’s similar — but more complex.

Mouthfeel in e-liquids includes:

  • Throat hit – the sharpness or smoothness felt when inhaling.
  • Vapour density – how light, full, or creamy the vapour feels.
  • Lingering sensation – the way flavours coat the mouth and tongue.

Flavour perception is only part of it. A liquid might taste good but fall flat if the mouthfeel isn’t right. That’s why brands can’t afford to overlook it.

The Role of PG, VG, and Nicotine

Three key ingredients form the backbone of every e-liquid: propylene glycol (PG), vegetable glycerine (VG), and nicotine. Together, they define mouthfeel.

  • Propylene Glycol (PG): Known for delivering a stronger throat hit and enhancing flavour sharpness. Ideal for vapers who want a punchier experience.
  • Vegetable Glycerine (VG): Produces thicker clouds and a smoother inhale, often favoured in sub-ohm vaping.
  • Nicotine (Freebase vs. Salt): Freebase nicotine gives a harsher throat hit at higher strengths, while nicotine salts allow for smoother, higher-strength vaping.

Balancing these elements is where the artistry comes in. A brand targeting beginner MTL (mouth-to-lung) vapers might lean on PG and nicotine salts for a smoother feel. Meanwhile, a cloud-chasing DTL (direct-to-lung) brand would focus on VG-heavy blends for dense vapour and a silky finish.

Flavour Compounds and Their Influence

Flavours themselves also play a big role in mouthfeel.

  • Menthol, mint, and citrus naturally create a sharper, more cooling sensation.
  • Custards, creams, and desserts provide a softer, richer, and more rounded mouthfeel.
  • Sweeteners and cooling agents can modify the vaping experience, either making it more refreshing or indulgent.

Layering flavours allows formulators to balance mouthfeel. For example, pairing a sharp lemonade with a smoother vanilla base can round off the edges while keeping the flavour exciting.

Device Compatibility: Why Hardware Matters

Of course, e-liquids don’t exist in isolation. The device used can dramatically change the mouthfeel.

  • MTL devices (common with pod systems and starter kits) deliver tighter airflow, higher nicotine strength, and more emphasis on throat hit.
  • DTL devices (sub-ohm tanks and mods) favour lower nicotine, high VG blends, and produce denser, smoother vapour.

For manufacturers, this means formulations need to be carefully designed with hardware in mind. An e-liquid optimised for a pod system won’t feel the same in a high-wattage mod — and vice versa.

The Consumer Perspective

Not every vaper wants the same mouthfeel. Some prize a sharp throat hit that mimics smoking, while others want silky smoothness and thick clouds. Preferences also vary by region and generation.

  • In the UK and EU, many ex-smokers still prefer a noticeable throat hit.
  • In the US and parts of Asia, smoother blends with high VG are often in higher demand.

Understanding these differences allows brands to tailor their products to their audience — and build loyalty through consistent satisfaction.

The Science Behind Consistency

One of the greatest challenges in e-liquid manufacturing is maintaining a consistent mouthfeel across large production runs. Even slight variations in ingredients or mixing can affect vapour texture and throat hit.

That’s why rigorous quality control and batch testing are essential. Manufacturers like Xyfil ensure every bottle delivers the same experience, from the very first production run to the thousandth. Consistency builds trust — and trust builds brands.

How Xyfil Masters Mouthfeel

At Xyfil, we understand that mouthfeel is more than an afterthought — it’s central to product success. Our formulation teams are experts in:

  • Balancing PG/VG ratios for target audiences.
  • Enhancing or smoothing mouthfeel with precise flavour layering.
  • Testing across different devices to ensure reliability.
  • Maintaining consistency through strict quality control.

Whether you want bold throat hit, silky smoothness, or dense vapour, we help you design e-liquids that deliver exactly the mouthfeel your customers are looking for.

Conclusion: Beyond Flavour – The Full Experience

Flavour gets the attention, but mouthfeel is what keeps vapers coming back. It shapes how consumers experience your product, from the very first puff to the last.

For brand owners, investing in the science of mouthfeel means investing in customer satisfaction, loyalty, and long-term success. And with the right partner, you can be confident every bottle delivers not just flavour, but a complete sensory experience.

And at Xyfil, that’s exactly what we specialise in.

Author Hannah Rubery Categories E-Liquid, Manufacturing, Packaging, Production Posted on

From Lab to Bottle: Inside the Life Cycle of E-liquid Production

When a consumer picks up a bottle of E-liquid, they see the finished product: a sleek design, an inviting flavour, and the promise of a smooth vape. But behind every bottle lies a detailed journey of research, innovation, compliance, and precision.

For brand owners, understanding this journey isn’t just interesting—it’s crucial. It highlights the level of care and expertise required to bring a flavour from an initial idea to a product that’s ready for the shelves. At Xyfil, we guide brands through every step of this process. Here’s a look at how it happens.

Concept & Market Research

Every great E-liquid begins with an idea. But in today’s competitive market, it’s not enough to follow instinct alone. Trends shift quickly, and consumers expect fresh, innovative options.

That’s why we begin with market research. By analysing flavour trends, seasonal demands, and regional preferences, we identify opportunities for our partners. Sometimes that means spotting the next big dessert flavour, other times it’s about refreshing a classic beverage profile. Collaborating with brand owners ensures that the flavour concept not only resonates with the market but also reflects the brand’s unique identity.

Flavour Development in the Lab

Once the concept is clear, it moves into the hands of flavour chemists. This is where science meets creativity.

Developing an E-liquid is about balance. Chemists work with flavour layers—top, middle, and base notes—to create a profile that delivers on taste and performs well in vaping devices. Factors such as coil technology, vapour production, and mouthfeel all influence the development process. The goal is to create a flavour that is bold, consistent, and enjoyable from the first inhale to the last.

Prototyping & Refinement

With the first formulation complete, prototypes are produced in small batches. This stage is all about refinement. Each recipe is carefully adjusted to ensure flavour accuracy, smoothness, and reliability across devices.

Brand owners are kept closely involved in this stage, giving them the opportunity to guide tweaks and align the final flavour with their vision. It’s a collaborative process that ensures the end result feels true to the brand story while also meeting technical performance standards.

Compliance & Safety Testing

In an industry where regulations vary across regions, compliance is non-negotiable. Before any product can reach the market, it must pass a series of rigorous checks.

Our compliance team ensures every formulation undergoes toxicology reviews, emissions testing, and restricted substance screening. From the UK’s TPD requirements to broader global standards, we manage the complex documentation and submissions so brand owners can launch with confidence.

This stage is about more than ticking boxes—it’s about guaranteeing safety and building trust with consumers.

Scaling Up: Manufacturing & Quality Control

Once approved, the flavour is ready for full-scale production. This is where our facilities step in, moving from small-scale prototypes to mixing, filling, and bottling lines capable of handling large volumes without compromising quality.

At every step, strict quality control checks are in place. From raw ingredient sourcing to the final sealed bottle, consistency is monitored and maintained. The aim is simple: every consumer should experience the same flavour and quality in every puff, no matter when or where they purchase the product.

Packaging & Branding

A great flavour deserves packaging that tells its story. This stage is where concept meets design, creating bottles and boxes that catch the eye while staying compliant with all labelling requirements.

For a dessert range, packaging might evoke indulgence and warmth. For a beverage range, it might lean toward freshness and energy. Whatever the brand vision, our in-house teams help align packaging with flavour identity—ensuring that what’s inside the bottle is reflected on the outside too.

Logistics & Distribution

The final step is ensuring the product reaches the right hands safely and efficiently. From storage and transport to navigating customs regulations in different regions, logistics plays a crucial role in keeping supply chains smooth.

By managing the details of packaging durability, shipping restrictions, and global distribution, we help brand owners avoid bottlenecks and keep their products moving seamlessly from production floor to consumer.

How Xyfil Supports Every Step

At Xyfil, we don’t just manufacture—we partner with brands. Our full-service approach means we’re with you from concept to completion, offering flavour development, compliance expertise, large-scale manufacturing, and packaging design all under one roof.

Whether you’re launching a new range or scaling an established one, our expertise ensures your journey from lab to bottle is efficient, compliant, and ready to capture consumer attention.

Conclusion: More Than Just a Bottle

The life cycle of an E-liquid is complex, but every stage plays a part in creating products that stand out, stay compliant, and deliver consistent quality. For brand owners, having a trusted manufacturing partner makes all the difference.

At Xyfil, we turn ideas into market-ready products—helping you focus on building your brand while we take care of the science, compliance, and production. Contact us today to get started.

Author Hannah Rubery Categories E-Liquid Posted on

Storytelling Through Flavour: Creating Emotional Connections

In today’s vape industry, flavour is no longer just about taste. With so many brands on the market in 2025, customers aren’t only buying nicotine delivery — they’re buying experiences. And experiences are built on emotion. The right flavour can spark memories, evoke moods, and even help consumers connect with a brand on a deeper level.

This is where storytelling through flavour comes into play. By shaping a range around a story, brands can create an emotional connection that sets them apart in an increasingly crowded space.

The Psychology of Flavour and Emotion

Flavour and emotion are tightly linked. Citrus blends, for example, are often associated with freshness, energy, and vibrancy — the kind of flavours that brighten your day.

Dessert flavours, on the other hand, lean into comfort, indulgence, and nostalgia, evoking the warmth of home baking or childhood treats. Beverage-inspired flavours can carry social associations — think of sipping a mojito on a summer’s evening or grabbing a cold cola at a party.

These associations matter. They transform flavours into feelings, and those feelings are what consumers take with them long after the last puff.

Why Storytelling Matters in Vape Branding

In a marketplace where every brand claims, “great taste” and “smooth vapour,” storytelling is what creates true differentiation. Consumers don’t just remember “Vanilla Custard” — they remember the brand that positioned it as the ultimate comfort flavour to unwind with at the end of the day.

Storytelling doesn’t just make flavours more memorable — it makes brands more human. It creates loyalty, helps ranges stand out on the shelf, and invites consumers to build their own personal narrative with the brand.

Building a Flavour Story Across a Range

For brands, the power lies in consistency. A flavour range isn’t just a catalogue; it’s an opportunity to tell a cohesive story.

  • Dessert-inspired ranges tap into indulgence, nostalgia, and self-reward — the moment of treating yourself.
  • Beverage-inspired ranges channel refreshment, energy, and social experiences — the flavours you’d enjoy with friends or as a pick-me-up.
  • Lifestyle-driven storytelling can also be applied: “morning coffee” flavours, “summer cocktail” flavours, or “late-night indulgence” flavours that align with consumer moods and daily routines.
  • Cultural inspiration adds another layer, drawing from global cuisines and experiences.

When done well, a range becomes more than a product line — it becomes a lifestyle identity.

Example: Dessert vs. Beverage Flavour Brands

Imagine two brands approaching storytelling differently:

  • A dessert-focused brand might build its entire identity around indulgence and nostalgia. Flavours like Tiramisu, Apple Pie, and Vanilla Custard don’t just taste good — they tell a story of comfort, cosiness, and timeless indulgence. The narrative is about treating yourself, evoking the warm familiarity of a favourite dessert.
  • A beverage-focused brand, on the other hand, positions itself as refreshing, social, and energetic. Mojito, Cola Ice, and Iced Latte become more than flavours; they’re invitations to experiences — a summer evening, a lively night out, or the first sip of coffee to kick-start the day.

Both approaches have storytelling power, but they speak to consumers in very different ways.

Narrow Focus vs. Diverse Range: Pros & Cons

For brand owners, the question often arises: should you focus on one flavour category or diversify across many? Each approach has its strengths — and its risks.

Narrow Focus (e.g., all desserts or all beverages):

  • Pros: Creates a strong, recognisable brand identity. Easier to build cohesive stories. Appeals deeply to niche audiences who love that category.
  • Cons: Can limit market appeal and lead to flavour fatigue. Expansion into new territories may be challenging if consumer tastes vary widely.

Diverse Range (mixing desserts, beverages, fruits, and more):

  • Pros: Broader market reach, appealing to a wide variety of demographics. Flexibility to adapt to different global markets and trends.
  • Cons: Harder to maintain a clear identity. Without careful management, the story risks becoming diluted or inconsistent.

The choice depends on brand ambition: do you want to be the go-to dessert vape brand or a versatile player that offers something for everyone? Both are viable strategies — but require clarity and consistency in storytelling.

The Role of Packaging and Marketing in Flavour Storytelling

Packaging is often the first chapter in your flavour story. Dessert-inspired brands might use warm cream tones, golden hues, or retro typography to convey indulgence.

Beverage-inspired ranges could lean on bold, refreshing colours and crisp, modern visuals.

Marketing then reinforces the narrative. Instead of selling “Strawberry Cheesecake,” you’re selling “a comforting evening indulgence.” Instead of “Cola Ice,” it’s “the refreshing kick to keep you going.” Storytelling transforms names into experiences that consumers want to relive again and again.

How Xyfil Helps Brands Tell Their Story

At Xyfil, we understand that flavours are more than just formulations — they’re vehicles for brand storytelling. Our team works with brand owners to craft flavour ranges that align with a clear narrative, whether you’re aiming for nostalgic desserts, energising beverages, or a diverse global mix.

From concept development to packaging design and compliance, we help brands create not just great-tasting products, but memorable stories that resonate with consumers.

Conclusion: Turning Flavours into Stories That Sell

In 2025, selling flavours isn’t just about taste. It’s about meaning, memory, and identity. Whether you’re building a brand around indulgent desserts or refreshing beverages, or offering a broad spectrum of experiences, storytelling is the bridge that transforms products into emotional connections.

The strongest vape brands will be those that don’t just sell e-liquids — they sell the experiences and emotions behind them.

Author Hannah Rubery Categories Branding, E-Liquid, Packaging Posted on

The Psychology of Colour in Vape Packaging Design in 2025

In today’s competitive vape market, your packaging isn’t just a container — it’s a silent salesperson. Before a customer even takes a puff, the colours, shapes, and design choices you make are already telling them a story about your brand.

And here’s the thing: people make split-second judgements. According to multiple studies in consumer psychology, colour is one of the biggest factors influencing purchasing decisions. In fact, for vape brands trying to cut through the noise, colour can be the difference between blending in and flying off the shelf.

So, let’s take a closer look at how colour works on a psychological level, the trends shaping vape packaging in 2025, and how you can future-proof your designs — even with talk of plain packaging on the horizon in the UK.

Why Colour Matters in Vape Packaging

Think of colour as the first handshake between your brand and your customer. It sets the tone, builds trust, and sparks curiosity — all before they even read your flavour name.

  • Blue often conveys coolness, calm, and trust.
  • Red is high-energy, passionate, and attention-grabbing.
  • Green suggests freshness, nature, and vitality.
  • Purple often carries a sense of luxury or indulgence.

In the vape world, colours also help tell a “flavour story.” A bright, sunny yellow might hint at zesty citrus, while deep purples and blues can suggest rich berry blends.

Without even realising it, your customer is making flavour assumptions based purely on the colour palette in front of them.

The Psychology Behind Colour Choices

Colour psychology isn’t just about making something look nice — it’s about influencing how people feel about your product.

Warm tones like reds, oranges, and yellows can create a sense of excitement and immediacy. Cool tones like blues and greens are more calming, often perceived as smooth, refreshing, or sophisticated.

Smart brands also use complementary or contrasting colours to help products stand out on the shelf. A tropical flavour might pop with a teal-and-orange pairing, while a dessert-inspired range could use creamy neutrals paired with indulgent golds.

The trick is balance: keep your core colour identity consistent for recognition, but don’t be afraid to refresh palettes seasonally to avoid colour fatigue.

Vape Packaging Trends in 2025

This year, we’re seeing a few clear packaging trends that work beautifully alongside colour psychology:

  • Minimalism with bold accents – Clean layouts paired with one striking colour element for instant recognition.
  • Gradients and holographic finishes – Adding a premium, modern edge to flavour storytelling.
  • Flavour-integrated imagery – Merging illustrative hints of ingredients with the colour scheme for a cohesive look.
  • Eco-friendly signals – Using earthy tones, recycled textures, and green-accented branding to signal sustainability.

These aren’t just design fads — they’re smart, visual ways to connect with your target audience and communicate your brand values instantly.

The UK Plain Packaging Discussions

Over the past year, there’s been talk in the UK about possible plain packaging requirements for vape products. Let’s be clear, nothing has been confirmed, but the conversation is ongoing, and it’s something brand owners should keep on their radar.

If regulations did move in that direction, it could mean restrictions on colour, standardised fonts, and the removal of imagery from vape packaging. While that might sound daunting, forward-thinking brands can prepare now:

  • Strengthen recognition beyond colour — through unique shapes, textures, and typography styles.
  • Develop strong in-store and digital branding that continues the visual identity beyond the packaging.
  • Work with compliant design partners who can adapt quickly to changing rules without losing your brand’s personality.

The goal is to make sure your brand remains memorable, even if the packaging playing field becomes more standardised.

How Brand Owners Can Leverage Colour Effectively

If you’re designing or refreshing your range in 2025, here’s how to make colour work harder for you:

  • Align your palette with your target audience and flavour themes.
  • Keep consistency for recognition but leave room for special edition palettes.
  • Consider cultural colour meanings if selling internationally.
  • Test your designs in the real world — sometimes what looks good on a screen behaves differently under retail lighting.

How Xyfil Can Help

At Xyfil, we understand that packaging isn’t just about compliance — it’s about connection. Our design team works with brand owners to create packaging that not only meets current regulations but also maximises shelf impact.

Whether you’re aiming for bold and attention-grabbing or preparing adaptable designs for potential plain packaging scenarios, we’ve got the expertise and production capabilities to make it happen — from concept to finished product.

Final Thoughts

Colour isn’t just decoration — it’s strategy. In a competitive, fast-moving industry like vaping, the right colour choices can tell your flavour story, spark emotional connection, and keep customers coming back.

By thinking ahead and embracing design trends that resonate with your audience, you can ensure your brand stands out in 2025 — and adapts seamlessly if the rules change.

Ready to rethink your packaging strategy? Get in touch with Xyfil today and let’s bring your brand vision to life.

1 2 3 … 15