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Tag Archives: e liquid manufacture

Xyfil Ltd   →  Blog   →  e liquid manufacture
Author Hannah Rubery Categories Branding, E-Liquid, Manufacturing, White Label Posted on

Protecting Brand Equity – White Label Manufacture

Protecting your brand and recipe is of the utmost importance to us which is why we employ strict procedures to ensure your brand equity remains protected. We wish to instil the utmost confidence in our customers when handling their brands, to make sure that products are not only safe and high-quality but also secure.

How do we protect brand equity?

In an industry ruled by flavours, trying to create new and unique flavour E-Liquids and vape devices, or creating higher quality flavours, is key. The last thing you want after all your hard work of establishing your brand’s flavours is to lose them. To ensure that brands’ flavours remain protected we established a series of procedures.

When our lab receives the flavour profile for your E-Liquids, they gather the necessary ingredients to make the batch of vape juice. However, each flavour ingredient is given a codename. When is orange not orange? When you are protecting a brand’s equity! To ensure that recipes remain confidential, those that process and produce the E-Liquids only ever see the codename version of flavour ingredients. This allows us to have fewer eyes on the actual recipe.

Once the flavour has been developed, you can then sample the flavours with our Flavour Specialist. Tweak and update the flavours and strengths depending on what you want to achieve or get ready to bulk produce it – we’re with you every step of the way.

Protecting your brand name

Ensuring brand equity doesn’t just stop at your flavour recipes. Making sure that your brand name continues to promote consistent quality is another one of our priorities. Mistakes can not only be costly in raw materials but in name. That’s why we employ a huge range of quality control procedures at every step of the process. Thanks to our training solidified by our GMP and ISO certification, we can produce high-quality products in safe environments to ensure the safety of your products.

Throughout the flavour creation process, your E-liquids go through a series of quality checks before mixing, before lab testing and after batch testing. Every step of the way there are quality checks to ensure zero errors. Up until the products leave our door, we can offer full batch-tracing at every step so that if errors do occur, we are able to quickly and efficiently go back to the source and correct it.

Our production warehouse is fully equipped to allow us to fulfil your bottling, filling and labelling requirements, as well as flavour development and E-Liquid manufacture. As one of the leading UK E-Liquid manufacturers, we are also able to ensure that compliance, quality, and safety is achieved for every product we produce.

If you would like to talk to us about manufacturing your latest product or kickstarting your own brand, contact us now.

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

Flavour Production, Quality Testing & Nicotine Extraction

Providing high-quality products and services is at the core of our mission here at Xyfil. We are one of the leading E-Liquid manufacturers in the UK, providing E-Liquid manufacture opportunities and more.

One of the key areas of our business is our ISO 9001 and GMP certified laboratory, and ISO 7 clean rooms where much of the manufacturing of E-Liquids begin. Meet the people behind the award-winning nicotine salt solutions and custodians of product quality control.

Nikita Mhatre – Production Manager & Quality Assurance

“We have implemented a quality management system which helps the business with planning and execution of delivering a quality product. From a production perspective, this means a companywide commitment to eliminate errors at every stage of the product development process - from product design to manufacturing.  A recent acquisition of GMP accreditations have also boosted the credibility of the company and created a competitive edge in an increasingly crowded market. The implementation of GMP standards inline with current quality standards remains essential as it helps to ensure consistency, acceptability of product quality and safety of the products also remains integral.”

As production manager for our lab, I oversee the formulation of products and work to create an effective and efficient task force. This is ensured by planning and delegating work to meet daily production goals. Not only this but I run the procurement for lab items along with the key E-Liquid ingredients, ensuring only the highest quality of food-grade PG, VG and pharma-grade nicotine. Products are not released from the laboratory to the production lines until they’ve been past final quality checks. It’s an important task that helps ensure quality and safety.

By implementing root cause analysis and taking corrective actions, I have helped to remove production constraints and improve product quality since taking the post. Our laboratory staff see continuous improvement and training to ensure the quality of products that are processed. As part of managing my team, recruiting for new positions, and ensuring my staff have no issues and work in optimum conditions, is paramount.

What does the day-to-day look like for Xyfil’s lab?

I can honestly say every day is a new day. Days can differ depending on the products and formulations we are running for our customers. We have six talented lab technicians and two supervisors who run our lab work.

At the start of the day, lab technicians are given a recipe list that contains encrypted flavour names to protect customers’ recipes. Quality checks go underway immediately to check the quality of the gathered ingredients and equipment. To minimise on wastage of ingredients and nicotine formulations, we run QC checks with tight parameters. Many formulations can be re-used whilst still holding a premium quality, but should they fail QC checks then these are disposed of.

Every stage of the process, from weighing flavours to the mixing of the ingredients, is overseen by a supervisor to reduce any possible human error. All work is signed off to allow for full tracking of the product so that if an issue does arise, we can track back the work and amend it to reduce any impact that it could create.

Once the batch is produced, a sample can be gathered after being authorised by the supervisor, to go for testing. This checks for irregularities, impurities, nicotine strength, consistency and more. After all these checks and tests have been completed and signed off, the product can then move to production.

We are constantly looking to improve our processes to create even more streamlined methods. Already we’ve seen improvements thanks to GMP standards and our hard work to achieve GMP certification. Having been able to increase our production capacity is a clear sign of our dedication to continual improvement.

E-Liquid suppliers with award-winning nicotine salts

There are two meaens of production that we provide with our laboratory facilities.

We provide bulk production services for white label E-Liquid manufacture. This includes us gathering the E-Liquid ingredients and flavourings to the spec of the customer’s recipe, producing the E-Liquids and flavours, and packaging these for our customers.

Our lab also offers a blending process for white label E-Liquids. This process relies on pre-existing formulations that we have developed and produced that are ready to go straight into production for customers’ products.

Due to the unique versatility of our lab facilities, we also offer ad-hoc requests for a variety of products, tailored to your needs. If you have an idea for a new nicotine-based or CBD product we can surely help. Apart from our white label capabilities, we offer bespoke solutions for product manufacture and development.

With our extensive resources and renowned nicotine salts formula, we are even able to offer the bulk dispatch of flavour ingredients and pre-mixed, finished nic salts for customers to use with their own formulations. Our aim is to help you create award-winning E-Liquid brands and flavours.

Ensuring premium quality E-Liquids and CBD

At Xyfil when we say premium quality, we mean it. I am proud to say that we are among the first E-Liquid manufacturers in the country to be certified to GMP standards, with ISO 22716:2007 certification recently having been reached.

One of the ways we continue to pride ourselves in our premium E-Liquids is through our method for nicotine extraction. Our laboratory boasts an HSE verified nicotine enclosed system for nicotine extraction, to ensure that staff are protected during the process and that the quality of nicotine is without impurities. Much like this, at every stage of the process in the lab, we run tight quality control checks that are repeatedly checked by supervisors to complete thorough analyses.

For example, before an E-Liquid formulation can be assembled, all ingredients and tools must be gathered and double-checked to ensure their quality and efficiency. Only after these pre-checks are fulfilled can the formulation be put together. Mixed flavours and batches are first checked for any impurities or issues before being sent for testing and analysis. Only after passing these initial checks can batches be sent for testing, and upon passing all criteria, then be sent onto production lines for bottling.

Overall, I’m proud of the team I have created and the lab I have helped flourish into one of the many necessary hearts of the business. If there was one thing I would say to any potential customer looking to have us manufacture their E-Liquids, it would be that you will never be disappointed. I look forward to working with you in the future.

If you have any questions in regards to our laboratory and E-Liquid manufacture, you can contact Nikita via LinkedIn here.

Author Hannah Rubery Categories E-Liquid, Xyfil Updates Posted on

Industry News – Lithuania Bans Flavoured E-Liquid

Lithuania becomes the next country to ban flavoured E-Liquids as part of a worrying trend we are starting to see. It becomes yet another country that has decided to ban flavours bar tobacco E-Liquids. A move that is highly questioned by vaping advocates.

They join the likes of the US, Finland, Ukraine, Estonia and Hungary who have also introduced flavour bans. Denmark and Netherlands are also looking to introduce the same ban.

Like many, they claim that by banning sales of flavoured E-Liquids, young adults are less likely to take up E-Cigarettes. A problematic opinion for many as flavoured E-Liquids have been shown to be a key factor for many vapers making the switch from smoking.

Why have they banned flavoured vapes?

The Lithuanian parliament, Seimas, have argued that sales of E-Cigarettes have been growing increasingly popular in Lithuania. By banning flavours other than tobacco they hope to stem the tide of sales, and potentially deter any possible young adults from taking up vaping. This ban will prohibit the production and sales of flavoured E-Liquid as of July 1st 2022, including those that don’t contain nicotine (shortfills).

There have been arguments that suggest Lithuania’s ban on flavours could potentially result in many vapers returning to cigarette smoking. Although Lithuania is one of Europe’s smallest countries with under 3 million residents, almost 30% of Lithuania’s adults smoke cigarettes giving them one of the highest smoking rates in the EU.

It’s important to note that Lithuania also ban the selling of E-Liquids or E-Cigarettes that contain vitamins or other additives, that create an impression that they are good or do less damage.

What does this mean for manufacturers and brands?

The ban in Lithuania means that E-Liquids (including non-nicotine shortfills) that contain flavours other than tobacco, will be banned in the country. Brands looking to remain on shelves in Lithuania will have to shift to tobacco flavoured E-Liquids or find an alternative around the ban.

At Xyfil we are actively on the alert for any market changes that could impact brands and help them manoeuvre the market. Whether it’s updates to regulations, changing flavour recipes, updating information on product labelling and more, we’re here to help. Our in-house compliance team are dedicated to ensuring that your products meet the necessary requirements for the market you wish to target. And with our 10+ years of experience in manufacturing, R&D, production, flavour development, logistics and more, Xyfil are more than ready to help.

Keep in the loop with changes to the industry, with Xyfil.

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

White Label Manufacture – From Idea to Reality

At Xyfil, we offer a range of white label manufacturing solutions to create and develop your brand, and to help your business thrive. Our professional teams are at your service, offering an extensive range of key services. These include all aspects of Branding & Design, Co-Packing, Production and Distribution. If you are looking to make your ideas a reality, let us help you get there.

Here’s everything you need to know about white label manufacture from Xyfil.

What is White Label Manufacture?

White Label products are manufactured by contract manufacturers and sold under your brand name. Here at Xyfil, we are experts in creating the product you want, and we ensure the process is as convenient as possible. You choose the packaging, labelling and design elements and we produce your products under our specifications.

Although the products are made to our specifications, your brand is in safe hands. We can boast about our award-winning nicotine salt formula and award-winning flavour department with renowned mixologists. Plus Xyfil has a proven record of 10+ years in the vaping industry.

Why choose White Label Manufacture?

As a leading OEM manufacturer, we offer white label solutions for your E-Liquid, CBD, Personal care products and more. If you have any non-edible, liquid-based product you wish to bottle, Xyfil can help. By partnering with us, we can provide your business with a range of benefits and give you a leading edge in the market.


SAVE TIME & MONEY

Time is everything and hitting the market with your brand while trends are still hot is key to making a success. With white label manufacturing we get your brand off the ground and onto shelves as quickly as possible. Benefit from fast turnaround times thanks to our experience in the industry, our ISO accreditations that ensure efficiency, and by always following GMP (Good Manufacturing Practices). 

Whether it’s selecting from our pre-made packaging, sending us your flavour concentrates, or letting us deal with compliance regulations, we can save your business time and money.  Choosing Xyfil means you can use our raw materials, ISO accredited facilities and expertise in creating award-winning brands and flavours. There’s no need to invest in your own state-of-the-art technology when we can open our doors to you.

EXPERIENCE

Take advantage of our 10+ years of experience in the industry. We’ve been here since the start of E-Liquids and E-Cigarettes hitting the UK market. Like many others we started from the ground up but established ourselves quickly as one of the leading manufacturers in the UK.

When TPD compliance hit the news and regulations began to change, Xyfil led the charge in creating the very first TPD compliant products to hit the UK market. This was thanks to our expertise and the methods in place to ensure adaptability. With dedicated teams in R&D, Compliance, Design and more, Xyfil have all the tools to get your business thriving.

COMPLIANCE

There’s nothing more daunting than paperwork so let us take care of it. Our 6-stage compliance process helps to ensure that your products adhere to market-specific regulatory standards and trade licences. We work closely with UK, EU and Middle East markets with the potential for many more international markets. Here at Xyfil we are well-versed in the compliance process with thousands of compliant products already in the market. Even when regulations change, we have the procedures in place and a dedicated compliance team, to quickly and efficiently make changes to ensure compliance.

DESIGN

Our creative studio can develop your logo, packaging, artwork, POS and marketing materials to effectively capture and communicate your brand vision. Whether you already have a basis for your desired branding, or just the base idea, our studio team will help take your brand on a visual journey and help make it stand out from the rest.

The advantages of white label

By working with us to create your white label products, you have access to: a ready-made catalogue of over 300 flavours, premium quality raw materials that are food-grade and pharma-grade, custom VG/PG ratios for shortfill products, a selection of VG/PG ratios for nicotine-containing products and more. The entire process is quality controlled to ensure the utmost safety and quality of all products that pass through our doors. This includes our FDA approved bottling solutions and full batch-traceability from ingredients to product.

Work with us to get access to premium quality goods that can take your brand to the shop floor. With many award-winning flavours and our nicotine salt formula that has quickly grown to be the number one choice for smokers looking to make the switch, Xyfil look forward to helping you make your brand a reality.

Contact us to learn more about how we can help and to get started on your journey.

Get to know us more and meet the team over on LinkedIn.

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

How E-Liquid has Evolved

We are one of the leading E-Liquid manufacturers in the UK, established in Preston, UK, since 2014. With over 10 years of experience in the industry, we have certainly seen it all. From the humble beginnings of E-Liquid and E-Cigarettes to the shake-up of laws and legislation that now define E-Liquid in the UK as a premium, high-quality product. Xyfil has been there. As one of the first to adapt to new changes in the market and establish TPD compliant E-Liquids, we look back at where E-Liquid and E-Cigarettes first began.

Where it really started

It wasn’t until the 1980’s that nicotine replacement therapies began to take off as our understanding of the harm of smoking grew. At first gum and patches were developed but offered little in terms of the cigarette-smoking habit. They only offered the ability to deliver nicotine to the system. This alone unfortunately isn't enough for many people to quit smoking.

That’s why in 2003 a Chinese pharmacist called Hon Lik decided to create a device that resembled traditional smoking. He created the very first E-Cigarette that used ultrasound waves to vaporise a nicotine solution - the very first E-Liquid. By the addition of resistance heating, it produced a vapour to inhale giving rise to the vaping we know.

The demand grows

Since then, there have been many new discoveries with E-Liquids and E-Cigarettes. We’ve come a long way from cig-a-likes and the first basic E-Liquids. Now we have devices with interchangeable parts, pod kits that are easily refilled, disposables for the ultimate convenience, and innovative ways to deliver nicotine and substantial flavours.

From new technology that creates smoother experiences with vaping, to brand new ways of mixing flavours. And with a healthy market, which continues to rise each year, it’s no surprise that demand for E-Liquids and E-Cigarettes continues to grow. As soon as vape tanks hit the market, the need for more variety with E-Liquids, in flavour, strength and different PG:VG ratios, became apparent.

How legislation changed the path of E-Liquid Evolution

You are more than likely already aware of the TPD regulations that came into effect back in May 2016. At the time this caused a stir as it meant many changes were necessary to sell E-Liquid in UK and EU markets. E-Cigarette tank capacities were limited to 2ml. Bottles of E-Liquid were limited to 10ml max capacity. Nicotine strength was capped to 20mg/ml and some flavourings were added to the ban list.

The biggest problem for vapers was certainly the bottle sizing as no longer could they carry around large bottles of E-Liquid to top up their tanks. This was especially an issue for heavy vapers or those using low resistance, high wattage devices. So, E-Liquids went through a new evolution giving rise to the shortfill. These bottles contained nicotine-free E-Liquid which allowed them to be produced in bottles larger than 10ml, and manufacturers then kept a little space in the bottle so that vapers could add their own 10ml nicotine shot.

Xyfil were one of the first UK manufacturers to implement these changes and successfully establish TPD compliant products in the market. Our manufacturing practices allowed us to make the necessary changes quickly and efficiently, from re-bottling E-Liquids to the new capped sizes to amending, re-printing and re-labelling products to comply with the regulations. A service we continue to offer today for those looking to bring products to UK, EU and UAE markets. Whether you are looking for manufacturing, white label services or compliance services, we are here to help.

Where we are today

The advancements in technology have also led to the creation of nicotine salts, a revolutionary way of delivering nicotine in E-Liquids, that prove beneficial for those looking to quit smoking. At Xyfil we offer an unrivalled nicotine salt formula that has continued to win awards each year.

Nicotine salts are extracted from the tobacco plant to create the purest form of nicotine, which provides a stronger hit many smokers/ex-smokers require. It's also kinder to the throat than similar strength freebase nicotine E-Liquids. It is one of the most efficient ways of taking nicotine due to its biocompatibility and is favoured by many vapers who say it delivers a more satisfying vaping experience. Speak to us if you are thinking of creating the next big nicotine salt brand.

It’s certain that E-Liquid can only continue to grow and evolve as the market continues to enjoy growth each year. Have you got a new idea for E-Liquids or perhaps a new flavour that you’re burning to create and hit the market with? Get in touch with us to see how we can help grow your brand and make your products the future of vaping.

Get to know us more and meet the team over on LinkedIn.

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

What Makes a Premium E-Liquid?

You have probably heard many businesses claim to offer premium or superior E-Liquids, but what makes an E-Liquid better than others? Is there any truth to the claim of a ‘Premium E-Liquid’? And how can we, here at Xyfil, help you with manufacturing your E-Liquids? Let’s take a look.

What makes an E-Liquid ‘premium’?

There are several factors that can make an E-Liquid, premium. The quality of the product, the ingredients and the processes that go into making them, all affect the quality of the finished product. All E-Liquids feature vegetable glycerine (VG) and propylene glycol (PG) as well as flavourings and nicotine (or are nicotine-free in the case of shortfills and longfills).

Quality VG and PG are a standard, but those using a poorer quality are not necessarily worse, but an impure solution should be avoided.

Food grade ingredients are usually the most common for manufacturing E-Liquids. However, some do also use pharmaceutical-grade base products. These of course are a little more costly to produce, which therefore raises the price of the overall finished product. This is because of the stringent testing that the ingredients undergo compared to food-grade products.

The true worth of a premium E-Liquid comes from the flavour profiles. E-Liquids may offer more diverse flavour combinations or simply more complexity and realism to a single flavour. That is not to say that all cheap E-Liquids are sub-par flavours, the key lies in the vapers. If those vaping the flavour have acute tastes and notice subtleties in flavour then a premium E-Liquid would be more beneficial. Those who struggle to taste hints of flavour, just like in wine and coffee, would enjoy cheaper, less premium versions just the same.

If you are looking to create a trusted, safe, top-quality E-Liquid that is truly premium, ticking these boxes is a must.

Xyfil manufactures premium E-Liquids

We strive to create premium E-Liquid brands alongside our existing customers and those looking to manufacture with us. Xyfil continues to create premium E-Liquids and we can back up the claim of ‘premium’ with how we work, and how we manufacture.

All our E-Liquids are produced and fully certified in an ISO:9001 accredited facility. This means we promise high efficacy and quality of the products we produce.

We also offer full traceability at batch level, of our raw materials, plus traceability of the people who have worked on the products. Being able to monitor the process every step of the way, ensures the safety of our products.

The plastic bottles used for all of our E-Liquid products are FDA approved, food-grade. Ensuring that every aspect of the product is quality controlled and compliant is a priority.

Our flavours are built from complex formulas with nuances of flavour, perfectly balanced to deliver what consumers are looking for. Quality flavours that feel and taste authentic.

The flavour ingredients we use are sourced only from the UK, European and US markets. This helps us ensure that they are food-grade safe, and also helps provide multiple supply lines should any issues arise that hinder possible supply chains.

When we produce different flavours, the process involved requires different steeping times for each blend. This helps us to create an optimal flavour that is unique to our blends.

For our nicotine-containing E-Liquids we use our award-winning nicotine salt formula to provide the smoothest nicotine hit in the market. Our nicotine salts are recognised worldwide and continue to achieve awards each year.

All of our base ingredients are European Pharmaceutical grade, the cleanest and safest grade available on the market. We don’t just guarantee customer satisfaction, we also prioritise customer safety by using only the most premium of ingredients.

Let us help you become a premium brand

We are a Toll Manufacturer which means that at any point of the manufacturing process, we can provide you with the service you need.

Not only do we offer manufacturing capabilities to provide premium E-Liquids, but we can offer whatever you require such as a bottling or labelling service. At Xyfil, we also offer compliance services for testing your E-Liquids to ensure TPD compliance and make your products market-ready.

Whether you are looking to produce your next E-Liquid range or would like to talk to us about any of our other services, you can contact us here.

Get to know us more and meet the team over on LinkedIn.

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