Tag Archives: packing

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.

How To Launch Your E-Liquid Brand in 2021.

Getting To Grips With The Market

In the 5 years between 2014 and 2019, e-cigarette sales rose by $12.3billion, and estimates suggest the current number of adults who vape could be around 55 million. With the industry growing quicker than ever before, there has never been a better time to launch your e-cigarette brand on the vape market. As a leading CBD and E-liquid manufacturer with clients worldwide, we know better than most the challenges faced by new producers breaking into the market. Let us talk you through the launch process.

Gaining Legal Recognition

So, you’ve worked with a top team of producers, manufacturers and designers – maybe us! - to turn your product ideas into a tangible, ready-to-market product. Nice work. What next?  

As you might expect, there’s a good number of regulations you’ll need to be compliant with, along with gaining respective approvals, before you can sell on the market legally. In the UK, these are governed by the MHRA (Medicines & Healthcare products Regulatory Agency). 

The TRPR (Tobacco and Related Products Regulations Act) updated by the EU Exit Amendment 2020 is your main point of essential compliance, and producers must submit information about their products to the MHRA to ensure full compliance via the MHRA Submissions Portal and European Common Entry Gate (EU-CEG). Submission is recommended six months before you intend to put your product on the market for sale. Turnaround time from submission to receiving approval can take up to 60 days, and fees do apply. 

As producer, it is your responsibility to ensure your products comply with TRPR requirements. Once the MHRA are satisfied your product complies, it is recorded as “declared” and you are free to supply your product for public sale in the UK. Our compliance team can help with this process to make sure that everything is up to standards.

The Perfect Marketing Window

Receiving legal status is half the battle. Once you’re confident you can place your product on store shelves with ease, it could be all too easy to take your foot off the gas. But don’t stop here! This is the perfect opportunity to amp up your marketing campaign to increase your audience and generate your first sales. 

Make the most of your social media channels: post partnership content or discount codes for purchases through your new suppliers to direct traffic. Paid promotions across your platforms will also be a great opportunity to capture new potential customers who may not already be aware of your brand. Recent newcomers, JUUL, had excellent success with these techniques back in 2017 – their social media engagement rose from a monthly average of 765 in 2015 to 30,565 in 2017, and they managed to capture more than half of the entire e-cigarette market share by the end of 2017!

Time To Get Started!

Hopefully, our handy run down of launching an E-liquid brand on the market has given you a better understanding of how the process works. While it can seem overwhelming, being prepared and consulting the experts are some sure-fire ways to make your first product launch as smooth and seamless as possible. If you need help with any aspect of CBD production, marketing, or launch – why not drop us a line? Get in touch at info@xyfil.com.

Create your own brand

5 Things You Need To Know About CBD

What is CBD?

CBD’s efficacy and versatility has earned it a prime spot in countless products across various industries, from cosmetics to the vape industry, food and drink, and health supplements. You’ll find it in almost everything from body butters to beers, but in spite of this much deserved hype, a lot of people are still in the dark about CBD’s origins and uses. Let’s run through some CBD essentials, and some of our favourite CBD facts.

CBD Is The Main Component of Cannabis

First things first, what is CBD, and where does it come from? Cannabidiol, or CBD, is one of 120 cannabinoids that makes up the cannabis plant. CBD is a non-intoxicating and non-euphoric psychoactive cannabinoid – meaning it can be great natural supplement to help you relax without getting you “high”.

Differences Between CBD Oils

Not all CBD oils are the same. Typically, they fall into three categories:

Full Spectrum – containing the full spectrum of CBD, including minor cannabinoids, cannabis-derived terpenes, and trace amounts of THC.

Broad Spectrum – containing a full spectrum of cannabinoids and terpenes, but without trace THC.

Isolate – a pure form of CBD with all other compounds removed. While some branding can be unclear about which category is contained in some products, it’s important to be sure which type you are buying. THC is a euphoric psychoactive cannabinoid, and as such does produce highs. THC is broadly illegal, and can increase depression and psychosis.

The Human Body Produces Cannabinoids

We know, sounds like science fiction, doesn’t it? But it’s true

Our bodies contain endocannabinoid systems, or ECS, complex cell-signaling systems with receptors in your central nervous system and peripheral nervous systems, particularly our immune cells. Research into ECS is still in its infancy – having first been identified in the 1990s – but scientists have so far uncovered that the ECS plays a role in regulating various body functions including sleep, mood, memory, and reproduction.

Our biological cannabinoids can help relieve pain, reduce inflammation, support the immune systems and ease symptoms of autoimmune disorders. It’s also been found that using CBD products as an additional supplement can help maintain our endocannabinoid systems, alongside the relaxation support offered by CBD supplements. A win win!

CBD Can Help Cancer Patients Manage Symptoms

Cancer is one of our most prolific diseases and innovative research is consistently increasing life expectancy and quality of life for sufferers year on year. Amongst this research, CBD has been touted to be a worthwhile aide to help cancer patients manage their symptoms.  

Cancer Research UK reports laboratory research so far as shown that CBD can cause cancer cell death or block cancer cell growth, stop the development of blood vessels which are needed for tumors to grow, and reduce inflammation. Although studies have had mixed results and more research is needed before anything conclusive can be decided, early discoveries are promising for the capabilities of CBD in cancer management.

CBD May Be a Helpful Supplement for Children

As CBD is non-intoxicating and non-euphoric, it is safe to give to most children in certain formats. In this article from Daily CBD, reviewed by Dr Abraham Benevides, M.D., gummies and low percentage oils are cited as the most appropriate means for CBD intake for children.

CBD supplements have been cited to help alleviate symptoms of anxiety, insomnia, asthma and nausea, as well as some skin conditions. It is, of course, essential to monitor CBD dosage when supplementing for children, and certain products – such as vapes – are not appropriate.

Packaging

Xyfil features in British Contract manufacturers & packers association.

Positive Trading, Recruitment Opportunities and Corporate Sustainability in Times of Global Uncertainty

As a leading UK manufacturer and contract packer, Xyfil Ltd was asked to feature in the September edition of our industry’s most well-respected magazine – Packaging News. 

Published by the British Contract Manufacturers and Packers Association, the BCMPA approached us to discuss recent trading in these challenging times, recruitment opportunities and corporate sustainability in the face of many global uncertainties such as Brexit and the Coronavirus pandemic. 

Please describe your business in 50 words

Xyfil is a leading UK manufacturer specialising in e-liquid, CBD and hand sanitiser products. We offer a range of manufacturing services including design and development, production, compliance, co-packing and distribution. Our Preston facility is equipped to produce 3.5 million bottles per month, delivering for local businesses and global partners.

How was business in the last 12 months?

Xyfil business has grown over the last 12 months. Our ability to pivot quickly has proved a key strength and provided resilience in the face of global and local uncertainties such as Brexit and the Coronavirus pandemic.

What markets do you operate in and are you targeting any new ones?

We operate primarily in the E-liquid market in the UK and Europe. However, we have diversified over the last six months into more generic filling and co-packaging markets. We are opening operations in the Middle East market and have been expanding on fulfilment for US clients looking to move into the UK and European markets. 

In light of the coronavirus pandemic, we began manufacturing hand sanitiser and supplying PPE to businesses, key workers and customers. Our existing infrastructure means we are able to produce and distribute hand sanitiser bottles in large quantities.

2020

In your sector, how practical is it to offer alternatives to plastic packaging? 

It is a little difficult as some of our plastic packaging requirements are driven by legislation. For example, Child Resistant and Tamperproof alternatives to small fill liquid packaging that can scale up are difficult to procure.  

However, our long-term aim is to be more environmentally sustainable and we actively look for alternatives to plastic packaging where possible. Many of our bottle types are already made from recyclable polypropylene (PP5) and we are working with our suppliers to ensure more of our products can be recycled.

How did lockdown immediately impact your business?

Most of Xyfil’s systems are cloud-based as our teams are globally located. We were fortunate that our infrastructure was already set up to allow us to transition rapidly ahead of lockdown to home working. Homeworking has proved more productive for some of our teams. The challenge has been around mental health and wellbeing as the uncertainties elevate anxiety levels. 

What impact has the pandemic had on trading?

Xyfil has been fortunate that we were able to pivot the capacity created by the slowdown in our core lines to support the fulfilment of frontline requirements such as hand sanitisers. The impact on trading has been minimal.

With rising unemployment, do you think it may be easier to recruit good staff in 2021?

Yes, without a doubt.

If you could change one thing in the industry, what would it be?

We would love to see the British Government support manufacturing and engineering in the UK more heavily. Like many filling and packaging industries, we have a heavy reliance on our machinery – much of which is produced outside of the UK. The talent and capacity in the UK to design and rapidly deliver cost-effective manufacturing equipment would help businesses like Xyfil to grow and become globally competitive.

Xyfil is a proactive purchaser of raw components from the UK but we consistently hit capacity issues with our UK manufacturing supply chain which means we have to backfill from abroad. These capacity issues indicate a lack of investment and development of the UK manufacturing sector. 

Article features Anisha Hansrod (Operations Director), Zain Patel (Business Development Manager), and Daniel Hollyman (Copywriter).

To read the full September edition of Packaging News Magazine and the online version of this article, please visit https://www.packagingnews.co.uk/digital-editions