Tag Archives: wholesale e liquid manufacture

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.

Compliance in the EU – All You Need to Know

When manufacturing and selling E-Liquids and E-Cigarettes in the EU, many of the regulations are the same as what we currently hold in the UK. Brexit and the exit-withdrawal agreement resulted in the UK adopting its own version, the Tobacco and related Products Regulations (TRPR). It also resulted in the Tobacco Products and Nicotine Inhaling Products (Amendment) (EU Exit) Regulations 2020. Whereas previously the UK was covered by the EU’s Tobacco Products Direction (TPD), or European Tobacco Products Directive (EUTPD) (2014/40/EU).

The EU Regulations

TPD and the EUTPD cover the manufacture, presentation and sale of all tobacco related products including E-Cigarettes. Much like the UK’s regulations, these directives govern the packaging, labelling and ingredients, alongside adverting restrictions, creation of a smoke-free environment, tax measures and activities against illegal trade, and acquiring anti-smoking campaigns.

For E-Cigarettes particularly, new rules were introduced:

  • minimum standards for safety and quality
  • information is provided to consumers of nicotine containing products
  • that protections are put into place to prevent children from starting to use the products

These rules came into effect as of May 2017 for any nicotine containing product:

  • restrict the maximum volume of E-Liquid in a single container to 10ml
  • restrict capacity of tanks to no more than 2ml
  • restrict nicotine strengths of E-Liquids to no more than 20mg/ml
  • be child resistant and tamper evident
  • not contain caffeine, taurine or colourings
  • be submitted to the EU-CEG (The EU Common Entry Gate)
  • include relevant warnings and information

As you may have realised, these are the same regulations we currently use in the UK with the only difference being the regulatory body that products should be reported to. For the EU, nicotine-containing products such as E-Liquids and E-Cigarettes must be reported to the EU-CEG. This regulatory body requires information on ingredients, emissions and toxicological data that is then accessible by the public for complete transparency. By doing so it ensures the quality and safety requirements are being met, and any non-compliant products will not be listed and should therefore be avoided.

Interestingly, in some EU countries, the EU-CEG is used to provide information on other products such as:

  • novel tobacco products
  • herbal products for smoking
  • nicotine-free E-Cigarettes

How Xyfil can help with compliance

“Our in-house team of experts are able to perform the necessary toxicological evaluations on the compounds detected during the analysis of your e liquid and its emissions. More critically, we also know how to gather this data into the format required by all European member states and complete the required submission for your business.”

Pradip, Compliance Officer, Xyfil.

You may be looking for help with establishing compliance for your existing products, before moving your products to EU markets. If so, our in-house compliance team can help by taking control of the process. From toxicology testing to filling out the paperwork and completing the process by informing the EU-Common Entry Gate, we can help you get your product to market without hassle.

Looking to create a new product to take the EU markets by storm? As a Toll Manufacturer, we are able to help you wherever you are in the process of product development. Be it manufacture, labelling & packaging, dispatch, marketing assets and of course compliance, Xyfil has you covered. With our white label manufacturing services for E-Liquid, CBD and cosmetics, we can efficiently offer quality products that comply with EU regulations. Backed by 10+ years of experience. With thousands of our products already available in the EU market, there’s never been a better time to start with Xyfil than now.

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

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.