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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.

Author Hannah Rubery Categories Compliance, E-Liquid, Regulations Posted on

UK Vape Tax: What It Means for Vapers and Retailers

The UK government has announced sweeping changes to vaping regulations, including a new tax that will reshape the industry. These measures aim to protect children from nicotine addiction whilst tackling the environmental crisis caused by disposable vapes. If you vape, sell vaping products, or simply want to understand these policy changes, here's everything you need to know about the upcoming vape tax and related regulations.

The new rules represent the most significant shift in UK vaping policy since e-cigarettes became widely available. From banning disposable vapes to introducing the first-ever vaping duty, these changes will affect millions of users and thousands of businesses across the country.

The Current Vaping Landscape in the UK

Vaping has become increasingly popular across all age groups in Britain. According to the Office for National Statistics, approximately 5.1 million people aged 16 and over used vapes or e-cigarettes in 2023. Daily vaping rates have risen to 5.9% of adults, with occasional use adding another 3.9%.

The highest usage rates appear among young adults, with nearly 16% of 16-24 year-olds now vaping. However, the most concerning trend involves children and teenagers. ASH (Action on Smoking and Health) found that 18% of 11-17 year-olds (around 980,000 children) have tried vaping, whilst 7% currently vape regularly.

Environmental concerns have also mounted as almost five million single-use vapes were discarded weekly in 2023, according to the Department for Environment, Food, and Rural Affairs. These devices contain lithium-ion batteries and circuit boards that can leak toxic compounds like cobalt and copper into ecosystems, potentially harming marine life and causing fires in waste collection vehicles.

Key Details of the UK Vape Tax

The new vaping duty will take effect on 1 October 2026, introducing a flat rate of £2.20 per 10ml of vaping liquid. This tax will apply alongside the existing 20% VAT that vaping products already attract.

The government has structured this tax to maintain vaping's role as a smoking cessation tool. Tobacco duty will increase simultaneously to preserve the financial incentive for cigarette smokers to switch to less harmful vaping products. This approach reflects the NHS position that vaping should primarily serve as part of adult smoking cessation programmes.

The Treasury expects this duty to generate significant revenue whilst deterring young people from taking up vaping. However, the tax rate remains considerably lower than tobacco duties, ensuring that vaping maintains its cost advantage over cigarettes for adult smokers seeking to quit.

Related Regulatory Changes

Disposable Vape Ban

The most immediate change took effect on 1 June 2025, when selling or supplying disposable vapes became illegal. Only reusable devices with rechargeable batteries, replaceable coils, and refillable chambers remain legal for sale.

Retailers breaking this law face minimum £200 fines in England, with repeat offences carrying prison sentences up to two years. Trading Standards officers can seize illegal single-use vapes, though consumers may still legally own existing devices.

Advertising and Marketing Restrictions

The Tobacco and Vapes Bill, currently progressing through Parliament, will ban vape advertising and sponsorship entirely. New restrictions will also limit flavours, packaging designs, and product displays that might appeal to children.

The British Medical Association has highlighted how manufacturers have deliberately targeted young people with attractive colours, branding, and appealing flavours like bubble gum or candy floss. These marketing tactics have contributed to rising youth vaping rates despite age restrictions.

Enhanced Enforcement

Authorities are intensifying crackdowns on illegal vapes, which often contain harmful chemicals or drugs beyond standard nicotine formulations. Trading Standards officers seized over six million illegal vaping products across England between 2022 and 2024, highlighting the scale of the black market problem.

Potential Impacts of the Vape Tax

Consumer Price Increases

The £2.20 per 10ml tax will significantly increase vaping costs for consumers. A typical 10ml bottle of e-liquid currently retailing for around £3-5 will see a price increase of over 40%. Heavy users purchasing larger quantities will face proportionally higher costs.

This price rise may disproportionately affect lower-income smokers who rely on vaping as their primary smoking cessation method. Public health advocates worry that increased costs might push some users back to cigarettes or toward cheaper, potentially dangerous illegal products.

Industry Transformation

Vape retailers and manufacturers must adapt quickly to these regulatory changes. Businesses will need to restructure supply chains, adjust pricing models, and ensure compliance with new advertising restrictions.

Smaller independent retailers may struggle with compliance costs and reduced profit margins, potentially leading to market consolidation. Manufacturers might focus more heavily on export markets where regulations remain less stringent.

Black Market Concerns

Higher prices often drive consumers toward illegal alternatives. The existing problem of illegal vapes containing unknown substances could worsen if legitimate products become significantly more expensive. Enforcement agencies will need additional resources to combat expanded black market activity.

Public Health Implications

The tax's impact on public health remains uncertain. Whilst higher prices might deter young people from starting to vape, they could also discourage adult smokers from switching to less harmful alternatives. The government must carefully monitor these competing effects to ensure the policy achieves its intended goals.

Expert Opinions and Industry Response

Public health organisations have offered mixed responses to the new tax. Many support measures to reduce youth vaping but express concern about potential unintended consequences for smoking cessation efforts.

The Royal College of Physicians maintains that vaping remains significantly less harmful than smoking and worry that excessive taxation might undermine its role in helping smokers quit. They emphasise the need for balanced policies that protect children whilst preserving access for adult smokers.

Vaping industry representatives argue that the tax level, combined with existing regulations, may be excessive. They point out that responsible manufacturers already avoid marketing to children and support age verification measures. However, they worry that legitimate businesses will suffer whilst illegal operators continue targeting young people without regard for regulations.

Some economists suggest the tax rate strikes a reasonable balance, generating revenue whilst maintaining vaping's cost advantage over cigarettes. They argue that modest price increases might actually improve the industry's reputation by discouraging casual youth experimentation.

Preparing for the Changes

If you currently vape, consider these steps before the tax takes effect:

  • Stock considerations: Whilst you cannot legally purchase disposable vapes after 1 June 2025, you can still own existing devices. However, consider transitioning to reusable alternatives that comply with new regulations.
  • Budget planning: Factor the new tax into your vaping budget from October 2026. The additional £2.20 per 10ml will significantly impact regular users' costs.
  • Retailer research: Identify reputable retailers who comply with age verification requirements and sell only legal products. Avoid illegal vapes that may contain dangerous substances.
  • Health considerations: If you don't currently smoke, health authorities strongly advise against starting to vape. The devices should primarily serve as smoking cessation tools for adults trying to quit cigarettes.

Looking Ahead: A Balanced Approach

The UK's new vaping tax and regulations represent a significant policy shift aimed at protecting children and the environment whilst preserving vaping's role in smoking cessation. Success will depend on careful implementation that addresses legitimate concerns without creating unintended consequences.

Monitoring will be crucial as these changes take effect. Policymakers must track youth vaping rates, adult smoking cessation success, black market activity, and environmental improvements to ensure the regulations achieve their intended goals.

The coming months will reveal how effectively these measures balance competing priorities: protecting young people from nicotine addiction, supporting adult smokers seeking to quit, generating government revenue, and addressing environmental concerns.

Stay informed about these changes through official government channels and reputable health organisations. If you're currently trying to quit smoking, consult healthcare professionals about the most appropriate cessation methods for your situation. The landscape may be changing, but support for those seeking to improve their health remains available.

Author Hannah Rubery Categories E-Liquid, Manufacturing Posted on

The Power of Limited Editions in the Vape Market

In an increasingly competitive vape market, standing out is harder than ever. With new products launching daily and consumer attention spans getting shorter, even the best brands can find themselves fighting to stay relevant. That’s where limited editions come into play.

More than just a marketing trend, limited-edition e-liquid and device ranges offer a powerful way to create urgency, attract attention, and connect with customers in new and meaningful ways. If you’re a vape brand owner looking to differentiate your product line, drive engagement, and boost sales—this might be one of your most effective tools.

Let’s explore how limited editions can help your brand shine, and how Xyfil can make the entire process seamless from idea to launch.

Why Limited Editions Work

There’s a reason limited editions have become a go-to strategy across industries—from sneakers and soft drinks to high-end cosmetics. In the vaping sector, they work especially well because they tap into a sense of urgency and exclusivity that resonates with today’s consumer.

When customers know that a flavour won’t be around for long, it naturally creates demand. The fear of missing out (FOMO) drives quicker purchasing decisions, leading to faster sell-through and stronger engagement. This urgency is amplified by how well limited editions perform on social media—unique products tend to be shared, reviewed, and talked about, giving your brand valuable organic exposure.

But limited editions aren’t just about hype. They’re also a smart way to test new flavour concepts without committing to full-scale production. By releasing short runs, you gain insight into what your audience responds to before investing heavily. And by aligning these launches with seasons, holidays, or pop culture moments, you can keep your brand fresh, relevant, and top-of-mind throughout the year.

Strategies That Sell

So, how do you make a limited edition truly effective? It starts with creativity, but success often comes down to execution.

One popular approach is to develop themed collections, such as a “Summer Fruit Series” or “Winter Warmers,” which can encourage customers to try multiple flavours within a set. Some brands take this further by building collaborations—partnering with influencers, artists, or even fashion brands to add a new layer of excitement and tap into other audiences.

Event-based drops are another strong strategy. Tying a limited edition to a trade show appearance, store anniversary, or exclusive online campaign creates a sense of occasion and gives fans a reason to tune in. Meanwhile, “mystery flavours” or fan-voted releases offer an interactive twist, giving your community a direct role in product development and increasing engagement even before launch day.

No matter which approach you choose, the goal remains the same: spark curiosity, create anticipation, and reward your audience with something they can’t get every day.

Making Limited Editions Work for Your Brand

To get the most out of a limited release, focus on a few key elements:

  • Flavour Selection: Strike the right balance between novelty and mass appeal. Unexpected pairings or bold profiles can work—but they should still be enjoyable for most.
  • Packaging Design: Unique packaging helps communicate exclusivity. It should visually distinguish the product from your core range while maintaining brand consistency.
  • Pricing Strategy: Decide whether your limited edition will be a premium offering or priced for wider accessibility. Each approach sends a different message.
  • Launch Plan: A successful limited edition is more than a flavour—it’s an event. Tease it early. Use countdowns, email blasts, and social previews to build momentum before launch.

How Xyfil Can Help You Launch Limited Editions with Confidence

At Xyfil, we understand that launching a limited-edition product isn’t just about having a good idea—it’s about executing it quickly, professionally, and in full compliance with regulations.

Here’s how we support vape brands like yours:

  • Rapid Flavour Development: Our expert flavourists work with you to craft truly unique profiles that align with your audience and seasonal trends.
  • Fast, Scalable Manufacturing: Whether you're creating 500 or 50,000 units, we offer the flexibility to produce the right quantity without sacrificing quality.
  • Regulatory Expertise: All limited editions are TPD and MHRA compliant, so you can launch with confidence—no shortcuts, no surprises.
  • Custom Packaging Solutions: Our design and packaging team can help you create standout visuals that match the exclusivity of your product.
  • White Label & Full-Service Options: From concept to finished product, Xyfil supports every step of the journey—ideal for brands who want to move fast without adding internal overhead.

Real Impact from Real Brands

We’ve seen firsthand how limited-edition releases can transform brand visibility. From increased social engagement and repeat orders to attracting new customer segments, these short-run products consistently deliver real ROI when executed well.

Whether you’re testing new flavours, launching a buzz-worthy collab, or refreshing your lineup for seasonal relevance, a well-planned limited edition can give your brand a powerful lift.

Final Thoughts: Ready to Create Something Unforgettable?

In a crowded market, limited editions offer something most vape products can’t: excitement. They invite customers to engage, explore, and act fast. And when done right, they can turn your existing range into a dynamic, ever-evolving story that keeps your audience coming back.

Want to launch your next flavour drop?
Partner with Xyfil, and let’s bring your vision to life—flavour, packaging, compliance and all.

Contact us today to start your limited edition journey.

Author Hannah Rubery 1 Comment on What Flavours Sell Best? Global Vaping Preferences in 2025 Categories E-Liquid Posted on

What Flavours Sell Best? Global Vaping Preferences in 2025

The world of vaping never stands still. New devices, new technologies, and evolving consumer tastes continue to reshape what flavours fly off the shelves—and which quietly fade away. As we move through 2025, it’s clearer than ever that understanding what flavours resonate globally isn’t just useful trivia for vape enthusiasts—it’s essential knowledge for brands and manufacturers hoping to stay ahead.

In this article, we’ll explore which E-liquid flavours are leading sales in 2025, how preferences differ by region, and what trends are likely to shape the rest of the year.

The Flavours Consumers Can’t Get Enough Of in 2025

1. Fruit Flavours: Still the Global Favourite

Fruit-based E-liquids continue to dominate worldwide. But tastes are evolving while classics like strawberry and blueberry remain popular, there’s been a noticeable surge in demand for tropical and exotic blends. Flavours such as watermelon, lychee, passionfruit, and dragon fruit have captured vapers’ attention, thanks to their refreshing profiles and the clean, bright notes they offer—especially when paired with chilled or iced variants.

2.  Beverage-Inspired Blends: A Growing Niche

Beverage-inspired flavours have carved out a strong following this year. Think sparkling cola, iced coffee, mojitos, or fruity bubble teas. These flavours offer complex, layered taste experiences that feel modern and indulgent—especially appealing to younger adult consumers looking for something different from standard fruit profiles.

3. Dessert & Candy Flavours: Sweet but Sophisticated

Sweet E-liquids are still in demand, but 2025 has seen a shift towards more sophisticated, layered desserts. Flavours like strawberry cheesecake milkshake, glazed doughnut, and vanilla custard pudding aren’t just sweet, they’re rich and complex, appealing to vapers who see flavour as an experience, not just a hint of sweetness.

4. Tobacco & Menthol Hybrids: Reinvented Classics

While traditional tobacco flavours continue to serve long-term adult smokers transitioning to vaping, brands have breathed new life into this category. Hybrid flavours—such as caramel tobacco, vanilla cigar, or icy mint tobacco—are growing in popularity, especially among older demographics and markets where sweet flavours face tighter regulation.

5. Limited & Seasonal Editions

Brands are increasingly using seasonal releases—think spiced apple in autumn or tropical punch for summer—to create excitement and test new ideas. Limited editions not only keep product ranges fresh but also tap into social media-driven hype and collector culture.

Regional Preferences: One Size Doesn’t Fit All

Consumer tastes don’t stop at national borders—and for brands selling internationally, these differences matter.

Europe:
Regulations have tightened on sweeter profiles, but fruit and menthol remain dominant. Refreshing mixed berries, iced watermelon, and mint blends continue to lead.

North America:
A broad, adventurous market. While fruit and candy flavours dominate, beverage-inspired flavours, rich desserts, and innovative hybrids (like peanut butter banana milkshake or root beer float) are rapidly growing more popular.

Asia & Middle East:
Consumers often prefer floral and cooling profiles—jasmine green tea, rose lychee, and ultra-iced fruit blends top sales here.

Latin America & Africa:
Tropical fruits—such as pineapple, mango, and guava—are favourites, sometimes combined with sweet tobacco or creamy notes for a local twist.

Understanding these nuances helps manufacturers tailor launches and marketing strategies to each market.

Why These Trends Matter for Brands

Knowing which flavours sell best isn’t just interesting—it’s critical for staying competitive. Brands that respond to changing tastes can capture new markets, strengthen loyalty, and reduce costly inventory missteps.

Data is key. Sales figures, flavour feedback, and social media trends all help brands refine product lines. Limited editions also offer a low-risk way to test new ideas, while keeping engaged consumers excited about what’s next.

Looking Ahead: What’s Next for Vaping Flavours?

While fruit will likely remain king, there are signs of new directions:

  • Fusion flavours: Unique blends like watermelon mojito, blueberry cheesecake frappe, or strawberry lemonade slush.
  • Natural & cleaner labels: Growing demand for naturally derived flavours and reduced additive profiles.
  • Super sweet, punchy flavours: With the fall of disposables in the UK, vapers will be looking for similar tasting alternatives which lean towards the super-sweet side of sugary flavours.

These shifts underline the vaping industry’s constant evolution—and the importance of innovation grounded in real consumer preferences.

Conclusion

In 2025, global vaping tastes remain refreshingly diverse. Fruit continues to lead, beverage and dessert profiles are growing, and local preferences shape what sells best in each region. For brands and manufacturers, the message is clear: listen closely to consumers, keep innovating, and don’t be afraid to experiment.

Which flavours do you think will dominate by the end of the year?

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

Finding a White Label Nicotine Pouch Manufacturer in Europe

As the demand for smokeless nicotine alternatives continues to rise, nicotine pouches are quickly becoming one of the fastest-growing segments in the European nicotine market. These discreet, tobacco-free products offer a convenient and modern solution for adult consumers seeking a cleaner nicotine experience — and the business opportunity is massive.

If you’re looking to launch your own nicotine pouch brand in Europe, partnering with an experienced white label nicotine pouch manufacturer is a smart, strategic move. The right partner can help you develop, produce, and scale a compliant, high-quality product quickly and efficiently. In this guide, we’ll explore what to look for in a white label nicotine pouch manufacturer — and why Xyfil is the trusted name helping brands break into this booming market.

What Is a White Label Nicotine Pouch Manufacturer?

White label manufacturing refers to a process where a company produces products that are rebranded and sold by another business as its own. In the context of nicotine pouches, this means you can launch your own branded product line without investing in your own production facility, raw material sourcing, or compliance infrastructure.

White label nicotine pouch manufacturing is ideal for:

  • New startups and entrepreneurs
  • Vape and tobacco brands expanding into smokeless products
  • Retailers developing private label alternatives

This model offers speed to market, reduced development costs, and access to proven, compliant formulations.

Why Europe Is Leading the Nicotine Pouch Movement

The European market has seen a significant uptick in nicotine pouch adoption, particularly in regions such as the Nordics, UK, Germany, and Eastern Europe. As consumers shift away from combustible tobacco and toward cleaner alternatives, nicotine pouches offer a compelling option: discreet, spit-free, and tobacco-free.

Key factors driving the growth:

  • Increased public awareness of harm reduction alternatives
  • Government regulations encouraging smoke-free products
  • Rapid retail expansion of pouch brands across supermarkets and convenience stores

However, launching in Europe also comes with regulatory complexity. Brands must comply with regional requirements, such as the EU Tobacco Products Directive (TPD), accurate nicotine labelling, and market-specific packaging guidelines. That’s why partnering with a manufacturer that understands European compliance is essential.

What to Look for in a European White Label Manufacturer

Choosing the right white label partner is more than just selecting a producer — it’s about finding an innovation and compliance partner. Here are the top features to prioritise:

GMP & ISO Certified Facilities

A good manufacturer should operate under strict quality standards, including Good Manufacturing Practice (GMP) and ISO certifications to ensure consistent product quality and safety.

In-House Regulatory Support

Compliance is non-negotiable. You need a partner who understands TPD registration, safety assessments, labelling laws, and export regulations across Europe.

Customisation Options

Flavour profile, nicotine strength, pouch size, moisture level, and even branding — your product should reflect your vision. Look for a manufacturer offering full flavour development and customisation.

Proven Track Record

Choose a manufacturer that has supported reputable brands and understands what it takes to succeed at scale.

Why Xyfil Is Your Go-To Nicotine Pouch Manufacturing Partner

At Xyfil, we don’t just manufacture — we bring brands to life. As a UK-based white label and contract manufacturer, we specialise in developing and producing premium nicotine pouch products for clients across Europe and beyond.

Here’s why Xyfil is a trusted partner for your brand’s success:

End-to-End Manufacturing Services

We handle everything under one roof — from concept and R&D, to production, packaging, and distribution. This means faster turnarounds, higher consistency, and full accountability.

In-House Compliance Expertise

Our regulatory team ensures that your nicotine pouch products are fully compliant with the latest UK and EU standards. We assist with TPD notifications, lab testing, CLP labelling, and safety data sheets — so you don’t have to.

Bespoke Formulation & Flavour Creation

Want to create a unique pouch flavour that stands out? Xyfil’s flavour technologists work with you to develop distinctive profiles tailored to your audience — from classic mint to exotic fruit blends.

Premium Manufacturing Standards

We operate from a GMP and ISO 9001-certified facility, ensuring pharmaceutical-grade quality across every batch. Our high-speed production lines support both small trial runs and large-scale volume.

Brand & Packaging Development

Beyond manufacturing, we help shape your brand identity — offering design, labelling, and packaging options that are shelf-ready and fully compliant.

From Concept to Shelf: Our Process

Launching your own nicotine pouch brand with Xyfil is seamless and transparent:

  1. Discovery – We begin with your goals, brand vision, and target markets.
  2. Development – Our R&D team works on your custom pouch formulations and flavours.
  3. Sampling & Feedback – You test the prototypes; we refine until perfect.
  4. Compliance & Registration – We handle all required testing and filings.
  5. Production & Packaging – Manufacturing begins in our state-of-the-art UK facility.
  6. Distribution Support – We assist with fulfilment, warehousing, and logistics if needed.

Whether you’re entering one country or launching across the EU, we make scaling simple.

Final Thoughts: Choose the Right Partner, Build a Stronger Brand

Launching a nicotine pouch brand is an exciting opportunity — but also a complex one. With evolving regulations, fierce competition, and changing consumer expectations, your success depends heavily on choosing the right manufacturing partner.

Xyfil is proud to be the trusted name behind some of the UK and Europe’s most innovative nicotine pouch products. With a focus on quality, compliance, and innovation, we help transform ideas into thriving brands.

Ready to Launch Your Nicotine Pouch Brand?

Contact Xyfil today to speak with our team about white label nicotine pouch manufacturing, custom product development, and launching in your target markets. Let’s build something great — together.

Author Hannah Rubery Categories Compliance, E-Liquid Posted on

UK Disposable Vape Ban & How to Stay Compliant in 2025

As of 1st June 2025, the UK government’s ban on disposable vapes is officially in effect — a landmark change that reshapes the vape industry and signals a new era for responsible innovation.

For brand owners and retailers, this isn’t just a regulatory hurdle. It’s a clear call to evolve — fast. Whether you’re already in the vape space or planning to enter it, understanding what this ban means and how to adapt is now mission-critical.

At Xyfil, we specialise in helping brands respond to change with agility, compliance, and confidence. Here's everything you need to know.

What Is the UK Disposable Vape Ban?

The UK government has enacted legislation prohibiting the manufacture, sale, and supply of single-use disposable vape devices. This includes commonly available closed-system vapes that are designed for short-term use and cannot be refilled or recharged.

Why the ban?

  • Environmental impact: Millions of disposable devices end up in landfills or as e-waste due to non-recyclable batteries and plastic casings.
  • Youth vaping: Concerns around youth access and underage use have led to growing pressure to restrict attractive, easy-access vape formats.
  • Public health policy alignment: The move aligns with the UK’s broader public health goals, including promoting smoking cessation through safer alternatives — not single-use products.

Enforcement will fall on manufacturers, importers, and retailers — with penalties for non-compliance expected to be significant.

What This Means for Brand Owners

For vape brands and product developers, the ban represents both a challenge and an opportunity.

Key Impacts:

  • Disposables are off the table — brands can no longer rely on the fast-selling, low-maintenance format to compete.
  • Loss of market share — if you don't pivot, your brand risks becoming irrelevant in regulated markets.
  • Product reformulation and redesign — disposable devices and e-liquid formats will need to be re-engineered for reusability and compliance.

But there’s a silver lining: consumers are already shifting their preferences. And brands that act quickly can establish themselves as leaders in a post-disposable market.

What Are the Compliant Alternatives?

With disposables banned, brand owners must now focus on longer-life vape formats that meet regulatory and environmental standards.

Here’s what’s compliant — and commercially viable:

  • Refillable Vape Kits
    Open-system devices that allow users to manually refill with E-liquid.
  • Closed Pod Systems with Replaceable Pods
    Devices that use pre-filled, click-to-connect pods — offering convenience without waste.
  • Reusable Vape Hardware
    Rechargeable devices paired with compliant E-liquids; ideal for long-term users.
  • E-liquids
    Whether you prefer a freebase brand of a Nicotine salt brand, there’s also nicotine free shortfill E-liquids.

These formats aren’t just compliant — they offer longer engagement with your customers and higher lifetime value per user.

How Xyfil Supports Brands Through the Transition

Adapting to new regulations can feel overwhelming, especially if you don’t have in-house manufacturing or compliance support. That’s where Xyfil comes in.

Here’s how we help:

Turnkey Manufacturing
We manage the full process from flavour development and device sourcing to filling, branding, packaging, and logistics.

Regulatory Expertise
Our dedicated compliance team ensures your products meet UK and global regulatory standards — including TRPR, CLP, and post-ban requirements.

Custom Product Development
Need to pivot quickly? We can reformulate your best-selling flavours into pod or refillable formats in record time.

Branding & Packaging Support
Update your product’s look and feel to match its new format and sustainability ethos.

With over a decade of experience in compliant vape manufacturing, we’re trusted by brands worldwide to deliver fast, flexible, and scalable solutions.

Your Next Steps: Future-Proofing Your Brand

Now that the ban is in place, the worst move you can make is inaction.

Here’s how to start:

  1. Audit your current product range – Identify all disposable SKUs and plan alternatives.
  2. Consult with a compliance expert – Ensure your new formats will meet both UK and international standards.
  3. Partner with an agile manufacturer – Work with a partner like Xyfil to accelerate reformulation and production timelines.

Conclusion

The disposable vape ban is not the end — it’s the beginning of a smarter, cleaner, more responsible future for vaping. And for brands willing to adapt, it’s a rare opportunity to lead the next generation of innovation.

At Xyfil, we’re here to make that transition seamless. From idea to shelf, we help brands stay compliant, competitive, and future-ready.

Author Hannah Rubery Categories Compliance, E-Liquid, Regulations Posted on

The UK Disposable Vape Ban: What It Means & How to Prepare

As of June 1st, 2025, the UK will officially ban the sale and manufacture of single-use disposable vapes. This regulatory shift is set to have a major impact on the vaping industry—from manufacturers and distributors to white-label brands and retailers. While this change presents a significant challenge, it also opens the door to innovation, sustainability, and long-term growth.

At Xyfil, we’re committed to helping our partners stay ahead of regulatory changes and future-proof their businesses. Here’s what you need to know about the upcoming ban and how you can prepare for what’s next.

What Is the UK Disposable Vape Ban?

The UK Government has announced that, effective June 1st, 2025, the manufacture and sale of single-use disposable vapes will be prohibited. The legislation is part of a wider initiative aimed at reducing environmental waste, protecting youth from nicotine addiction, and supporting the UK’s public health goals.

Key drivers behind the ban include:

  • Rising concerns over youth vaping
  • Significant environmental waste from non-recyclable devices
  • Pressure to meet net-zero and circular economy targets

This means brands relying heavily on disposables must act fast to adapt and remain compliant.

How the Ban Will Impact Vape Brands

Whether you’re a white-label brand or a large-scale distributor, this regulation will change the way you operate. Key implications include:

  • Loss of Key Product Lines: Many of today’s top-selling products will no longer be allowed on the market.
  • Stock Management Pressures: Businesses must sell through or remove existing disposable inventory before the ban.
  • Regulatory Risks: Non-compliance could lead to fines, brand damage, or delisting from major retailers.
  • Brand Identity Shifts: Companies built around disposable convenience will need to pivot fast to retain their market share.

Key Challenges to Anticipate

1. Overstock Dilemmas

Distributors and retailers may find themselves holding unsellable stock after June 1st. Efficient forecasting and clearance strategies will be essential.

2. Customer Retention Risks

Consumers who rely on the simplicity of disposables may be hesitant to switch. Education and accessible alternatives are key to keeping them onboard.

3. Innovation Under Pressure

Brands must quickly pivot to alternative product formats, ensuring quality and compliance without sacrificing the user experience.

How Vape Brands Can Prepare for the Ban

To stay competitive and compliant, brands should act now. Here’s how:

Conduct a Product & Compliance Audit

Evaluate your current product range and packaging for any non-compliant items. Prioritise the transition of high-performing disposable SKUs into alternative formats.

Communicate with Retail Partners

Work with your retail channels to develop sell-through strategies and help them prepare for the product switch.

Invest in Product Development

Now’s the time to diversify your portfolio. Consider developing refillable pod systems, closed-loop devices, or rechargeable disposables with replaceable pods—formats more likely to remain compliant.

Educate Your Consumers

Use your platform to guide users through the transition. Highlight sustainable, easy-to-use options that offer a similar experience to disposables.

Reposition Your Brand

Refocus your messaging around sustainability, longevity, and responsible vaping. Use this shift as a chance to align your brand with future-forward values.

How Xyfil Can Support Your Transition

At Xyfil, we specialise in helping brands adapt, innovate, and thrive in a rapidly evolving regulatory landscape. Here’s how we can help:

White-Label & OEM Product Development

We help businesses create custom, compliant vape products—from concept to shelf. Our experts are already developing next-gen devices that meet post-ban requirements.

In-House R&D Team

Our innovation team works with partners to reformulate and redesign vaping solutions, maintaining performance while staying within new legal frameworks.

UK-Based Manufacturing

With ISO-certified facilities and TPD compliance expertise, we provide scalable manufacturing with full regulatory assurance.

Sustainable Solutions

We’re leading the way in designing eco-conscious vaping alternatives—from recyclable materials to longer-lasting, refillable devices.

The Opportunity Behind the Ban

This is more than just a challenge—it’s a turning point for brands to lead the industry forward. The ban gives innovative businesses the chance to:

  • Launch new product lines built on sustainability and technology
  • Attract environmentally-conscious consumers
  • Set new standards for quality and compliance

Brands that move swiftly will have first-mover advantage in a newly shaped market.

Final Thoughts

The UK disposable vape ban marks a significant shift—but with the right strategy, it can be a launchpad for growth, not a setback. The future of vaping is sustainable, compliant, and consumer-focused. At Xyfil, we’re here to make that future possible for your brand.

Get in touch today to find out how we can help you transform your product range and prepare for success in a post-disposable world.

Author Hannah Rubery Categories E-Liquid Posted on

Alarming Rise in Smoking Rates in England

For the first time since 2006, smoking rates in England are increasing, presenting a significant public health challenge. A recent study conducted by University College London (UCL) revealed that, while smoking rates have steadily declined over the past decade, certain regions—particularly in southern England—have seen a recent uptick. Given that smoking remains a leading cause of preventable death globally, this trend raises critical questions about effective strategies to reverse it.

One increasingly recognized harm-reduction tool is vaping. Supported by a growing body of evidence, vaping is proving to be a safer alternative to traditional tobacco products. This blog will explore how vaping can contribute to reducing smoking rates across England and beyond.

Smoking in England: Examining the Trends

Between 2006 and 2024, smoking rates in England saw a significant decline, dropping from 25.3% to 16.5%. This dramatic reduction was largely attributed to public health campaigns, comprehensive smoking bans, and improved access to cessation programs. However, since 2020, progress has stagnated, with some regions even experiencing a worrying increase in smoking rates, suggesting that the fight against smoking is far from over.

Data from the UCL study reveals notable regional trends, highlighting disparities across the country:

  • South-West England recorded the largest increase, with smoking rates rising by 17% between 2020 and 2024. This sharp rise raises concerns about the effectiveness of local policies in maintaining previous progress.
  • Southern England, including the South-East and London, also saw sizable increases, with smoking rates rising by 9% and 8%, respectively. These areas, traditionally seen as leaders in low smoking prevalence, may be facing new challenges, including post-pandemic lifestyle habits and reduced funding for cessation services.
  • Northern England, in contrast, continued its downward trend, achieving a 9.7% reduction in smoking rates during the same period. This progress may reflect sustained investments in public health initiatives and targeted support for smokers in these areas.

The rise in smoking rates across southern regions signals a concerning regression, potentially driven by a combination of post-pandemic lifestyle changes, increased stress levels, and decreased access to smoking cessation resources. This trend emphasizes the need for renewed focus on tailored public health strategies to prevent further backsliding and to continue reducing smoking rates nationwide. Without urgent action, the hard-fought gains of the last two decades may be at risk of reversal.

Potential factors that could cause increasing rates

Several factors might account for the increasing rate of smoking in England, particularly in the south. Economic uncertainties and the rising cost of living could be contributing to heightened stress and anxiety, leading some individuals to turn to smoking as a coping mechanism.

An increasing number of both smokers and non-smokers in England hold the belief that vaping is as harmful, or even more harmful than smoking traditional cigarettes. This misconception could be due to a lack of clear public health messaging or widespread misinformation. Research has consistently shown that while vaping is not risk-free, it is significantly less harmful than smoking. A study published by Public Health England highlights that vaping is at least 95% less harmful than smoking cigarettes. Misunderstandings about the relative risks may discourage smokers from transitioning to vaping as a less harmful alternative.

These combined influences highlight the complexity of reversing this trend and the need for comprehensive strategies.

Reclaiming Progress in the Fight Against Smoking

England has achieved notable success in reducing smoking rates, but a recent rise highlights the urgent need for innovative and inclusive approaches. Vaping offers a less harmful alternative to traditional cigarettes and represents a valuable opportunity to address this challenge.

Regional disparities in smoking prevalence emphasize the importance of tailored interventions. Integrating vaping into public health strategies could play a critical role in advancing efforts toward a smoke-free future.

For smokers seeking to quit, vaping can serve as an effective first step toward a healthier lifestyle. Access reliable resources and begin your journey today—your future self will benefit from the change.

Author Hannah Rubery Leave a comment Categories E-Liquid, Regulations Posted on

Bulgaria’s Vape Ban and What It Means for the Industry

Bulgaria has been sparking debates among vapers, vape brand owners, and policymakers. Initially proposed as a complete prohibition, the vape ban has shifted focus, raising crucial questions about its implications on both industry and public health.

This post examines Bulgaria’s evolving stance on vaping laws, the challenges posed by European Union (EU) regulations, and what the potential restrictions could mean for brands and users alike.

The Initial Proposal and Its Evolution

On 12 February 2025, the Bulgarian National Assembly unanimously voted for a bill to ban all vaping products, including zero-nicotine variants. This sweeping move aimed to eliminate the sale, distribution, and advertising of e-cigarettes across the country. The decision came in response to rising concerns around vaping products, spurred by a tragic incident involving a black-market THC vape.

However, this ambitious total ban faced immediate complications. By late February, Bulgarian lawmakers started revising their approach. Now, they are considering alternatives like banning only disposable vapes or flavoured products, instead of outlawing vaping entirely.

The revision isn’t just about practicality; it also highlights the difficulties of navigating EU regulations, which govern vaping products as legal consumer goods across member states.

EU Regulations and the Complexity of a Total Ban

Implementing a full ban on vaping products in Bulgaria would be incredibly challenging due to EU laws and the bloc's single-market economy principles.

Under the EU’s 2014 Tobacco Products Directive (TPD), vaping products are legal and regulated. This makes outright bans difficult to justify within the framework of the single market, where goods that comply with EU regulations are allowed to be sold freely across member states. Any national restrictions must be notified to the European Commission through the Technical Regulations Information System (TRIS), a process that allows EU citizens and member states to provide feedback on proposed laws.

As the chairman of Bulgaria’s health committee, Kostadin Angelov, noted, pursuing a full ban could take years due to likely objections at the EU level. Such a measure may even be deemed as market interference, rendering it practically impossible to implement.

By comparison, bans on disposable vapes or flavoured products stand a greater chance of securing approval under the TRIS framework. Similar restrictions have been approved in other European countries, making this a more viable path for Bulgarian lawmakers.

The Focus Shifts to Disposable Vapes and Flavours

Shifting the focus towards banning disposable vapes or flavoured products offers a less contentious alternative for the Bulgarian government. Disposable vapes, often criticised for their environmental impact, and flavoured products, perceived as appealing to younger demographics, have already been targeted by restrictions in other EU countries. These types of bans could be enacted more quickly, taking just a few months once permission is granted through the TRIS system.

Despite being less dramatic than a total ban, these restrictions are still significant. Disposable vapes make up a large portion of the vaping market due to their affordability and convenience. Likewise, flavoured products play a critical role for users transitioning away from traditional cigarettes. According to the World Vapers’ Alliance (WVA), access to flavours is a key factor in helping smokers quit and maintain their switch to safer alternatives.

Implications for Vapers and Vape Brands

For vapers, any form of restriction could reduce access to regulated vaping products. The WVA has warned that limitations, particularly on widely used items like disposable vapes, could push users back towards smoking or unregulated black-market products. Bulgaria already has the highest smoking rate in the EU, with 37% of adults smoking, and restricting harm-reduction tools could hinder efforts to reduce this alarming figure.

For vape brands, these developments present both challenges and opportunities:

  • Compliance Hurdles: Companies operating in Bulgaria may need to adapt swiftly to new regulations, potentially phasing out disposable products or altering their flavour offerings.
  • Market Shifts: A flavour ban could drive demand for unflavoured or tobacco-flavoured E-liquids, requiring brands to pivot their product lines to remain competitive.
  • Black Market Risks: The banning of disposable vapes or flavours could inadvertently fuel illicit trade, similar to what has happened in other regions with restrictive vaping laws.

Brands with a strong focus on community engagement and harm-reduction advocacy may find opportunities to influence the development of more balanced, evidence-based regulations.

A Broader Debate on Harm Reduction

Bulgaria’s attempt to tackle vaping through restrictive measures has reignited an ongoing debate about harm-reduction strategies. Countries like Sweden, New Zealand, and the UK have embraced harm reduction and are on track to achieve "smoke-free" goals. By contrast, Bulgaria’s high smoking rate underscores the importance of providing safer alternatives rather than limiting access to them.

The WVA has strongly criticised Bulgaria’s proposed ban, stating that it ignores evidence-based policymaking. Their open letter to lawmakers urges the government to adopt regulations that promote harm reduction, such as stricter enforcement against black-market products and improved public education on vaping safety.

What’s Next for Vaping in Bulgaria?

The outcome of Bulgaria’s legislative process could have far-reaching implications for the vaping industry across Europe. Whether the focus remains on disposables, flavours, or something else entirely, this situation highlights the need for balanced regulations that protect public health without stifling access to harm-reduction tools.

For vapers and vape brand owners in Bulgaria, staying informed and engaged in the legislative process will be key. Engaging with advocacy groups like the WVA can help amplify voices calling for sensible, evidence-based approaches to regulation.

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

An Introduction to the Nicotine Pouch Industry in the UK

Nicotine consumption is undergoing a significant transformation, particularly in the UK, where traditional methods like smoking are being replaced by modern, smoke-free alternatives. Nicotine pouches are at the forefront of this shift, offering an innovative, discreet, and health-conscious solution that’s increasingly capturing the attention of consumers and businesses alike.

This blog will explore the growing nicotine pouch industry, its impact on the UK market, and how our manufacturing solutions can help meet rising demands. Let's begin with the basics.

What Are Nicotine Pouches?

Nicotine pouches are compact, pre-proportioned, smoke-free products designed for oral use. They contain either tobacco-derived or synthetic nicotine blended with food-grade fillers, flavours, and other approved ingredients. Users place the pouch under their lips, allowing nicotine to be absorbed without combustion, smoke, or odour.

First introduced to the UK in 2019, these pouches have gained traction as a safer and more convenient alternative to smoking or vaping. Several leading brands, such as Velo, Zyn, and Nordic Spirit, have established themselves in this growing market, and the demand for nicotine pouches continues to soar.

Market Growth and Trends in the UK

The nicotine pouch industry in the UK is flourishing. With an estimated market size of $247.6 million in 2024, it’s projected to grow at a steady CAGR of 7.6%, reaching $386.2 million by 2030. Here’s what’s driving this growth:

  • Rising Popularity: British adults are increasingly adopting nicotine pouches, with usage almost doubling from 2020 to 2024 to 5.4%.
  • Health Consciousness: Many consumers view nicotine pouches as a cleaner and less harmful alternative compared to traditional smoking or vaping.
  • Sales Surge: UK sales figures have seen explosive growth, with a 289% increase between 2019 and 2024 alone.
  • Innovation in Flavours: A wide variety of flavours—ranging from mint and citrus to novel options like dessert-inspired blends—align with evolving consumer preferences.

This upward trajectory underscores the growing prominence of nicotine pouches, particularly among younger adults and former smokers looking for discreet, convenient ways to consume nicotine.

The UK’s Regulatory Landscape

The regulatory environment for nicotine pouches is a vital consideration for both manufacturers and retailers. While not as strictly regulated as tobacco products, in fact they are regulated under the General Product Safety Regulations (GPSR), the following rules apply:

  • Taxation: Nicotine pouches in the UK are subject to VAT at 20%, but excise duty does not apply.
  • Legal Considerations: Sale to individuals under 18 is prohibited, and products must adhere to General Product Safety Regulations (GPSR).
  • Advertising: Brands can advertise nicotine pouches responsibly, focusing on factual product information.
  • Packaging: Products must have child-resistant packaging and clear labels, including health warnings and safety guidelines.

Current regulations may evolve, so compliance and regular updates are essential for businesses seeking to enter or grow within this market.

A Closer Look at Market Segmentation

The UK nicotine pouch market can be divided into several categories, catering to diverse consumer preferences and needs.

Tobacco-Derived vs Synthetic Nicotine

  • Tobacco-derived pouches held a dominant market share of 97.81% in 2024, driven by their established consumer base.
  • Synthetic nicotine pouches are gaining ground, with a projected CAGR of 14.4% from 2025 to 2030, appealing particularly to health-conscious users.

Flavoured vs Unflavoured Pouches

  • Flavoured options account for 94.04% of revenue due to their appeal among younger demographics.
  • Unflavoured pouches cater to users seeking a more natural experience.

Strength Preferences

  • From light (2 mg) to extra strong (over 8 mg), products cater to a wide spectrum of users.
  • Extra strong pouches are favourites among experienced users, while beginners often prefer lighter concentrations.

Sales Channels

  • Offline Channels dominate the market, but Online Channels are rapidly growing at a CAGR of 11.0%, thanks to their discreet purchasing options and broader accessibility.

Nicotine Pouches as an Alternative to Vaping

Regulatory changes and growing concerns about vaping have led many consumers to explore alternatives like nicotine pouches. Here’s why they’re gaining preference:

  • Discreet Use: Nicotine pouches can be used anywhere without smoke or vapour.
  • Convenience: No maintenance, charging, or refilling—just open the pack and enjoy.
  • Cleaner Experience: No combustion or harmful by-products makes it an appealing choice for health-conscious users.

With these advantages, nicotine pouches are presenting themselves as an alternative or an attractive addition to vaping brand's product ranges, aligning with the needs of modern, on-the-go consumers.

Manufacturing Nicotine Pouches with Precision

At the heart of the nicotine pouch industry lie meticulous manufacturing processes. Here’s how we ensure each product meets the highest quality standards:

1. Premium Ingredients

  • Pharmaceutical-grade nicotine and food-grade fillers ensure safety and reliability.

2. Advanced Blending and Testing

  • Ingredients are mixed in pharmaceutical-grade V-blenders, ensuring uniformity.
  • Comprehensive laboratory tests, like nicotine assay and pH analysis, maintain consistency.

3. High-Speed Pouch Filling

  • Dedicated filling machines accurately fill and seal each pouch, maintaining precision and hygiene.

4. Customization Options

  • Standard strengths (4 mg, 6 mg, 9 mg) and various flavours are available.
  • Bespoke formulations can be developed upon request.

5. Packaging Excellence

  • Durable, child-resistant polypropylene cans with 20 pouches each keep products fresh and accessible.

How We Can Help

Whether you’re entering the nicotine pouch market or expanding your product line, our expertise ensures you’ll meet consumer demands efficiently. Here’s what we offer:

  • Contract Manufacturing: Provide us with your formula, and we’ll ensure premium production.
  • White-Label Solutions: Adopt our existing product range, customised with your branding.
  • Bespoke Development: Collaborate with us to create unique flavours, strengths, and blends.

Our reliable logistics services and fast turnaround times (3 weeks for reorders) mean you can focus on growing your brand while we handle the rest.

The Future of the Industry

With accelerating growth, regulatory focus, and expanding consumer interest, nicotine pouches are more than a trend—they’re a promising future for nicotine consumption. From discreet use to innovative flavours and premium manufacturing, the market holds vast opportunities for businesses that act now.

Interested in manufacturing nicotine pouches? Contact us today to learn how we can support your vision with expert manufacturing and market-ready solutions.

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