How Are Nicotine Pouches Made?

Some might say nicotine pouches are like a gift sent from above. In reality, these little sachets of flavor have only become what they are today because of a tightly controlled manufacturing process.

Curious about what exactly that looks like? This article will run through the ingredients nicotine pouches contain, the manufacturing process behind them, and some other tidbits related to their creation.

What are Nicotine Pouches Made Of?

When looking at a nicotine pouch, the white, pillow-like sachet is the first thing that’s visible. These sachets are made of plant-based fibers, which have a soft outer texture that feels comfortable in the mouth and enables the release of nicotine.

But inside the pouches lie a whole host of other ingredients.

Most notably, there’s nicotine.

Then there are the flavorings, which give the products their unique taste. Whether the taste profile in question is a popular flavor like mint or something more unusual, flavorings usually take the form of e-numbered food-grade flavors or sweeteners like xylitol.

Additional ingredients in nicotine pouches include:

• Stabilizers. Enhance flavor, maintain the right consistency and moisture, and act as a binding agent (e.g., vegetable glycerine and propylene glycol).
• Fillers and texturizers. Impact nicotine release and the pouch mouthfeel (e.g., gum and cellulose).
• pH modifiers. Ensure the nicotine is released as desired (e.g., sodium carbonate or bicarbonate)

How Are Nicotine Pouches Made?

The manufacturing behind nicotine pouches is an automated process carried out in factories using state-of-the-art technology.

Advanced equipment used includes filling machines, packaging lines, and mixers, which are designed to handle large volumes while maintaining precision.

Most manufacturers aren’t willing to reveal the secrets behind their nicotine pouch manufacturing processes (and they probably wouldn’t be particularly thrilling to the average person anyway).

But below, we’ve outlined the basic processes involved in nicotine pouch production.

1. Nicotine Extraction and Purification

To keep nicotine pouches tobacco-free, manufacturers must isolate the nicotine from tobacco. There are two ways to achieve this:

• Extracted nicotine from tobacco plants by isolating the nicotine from the leaves through solvent extraction.
• Making synthetic nicotine in a lab using molecular technology by rearranging molecules to mimic tobacco leaves.

This nicotine then undergoes a purification process to eliminate impurities and ensure premium standards.

2. Blending of Ingredients

Next, the nicotine is transformed into a powder. It’s then blended with the other ingredients outlined above, such as sweeteners and stabilizers.

Manufacturers then place everything into white permeable sachets, therefore combining all ingredients.

3. Quality Inspection

The two steps outlined above explain the basic production process behind nicotine pouches.

However, most manufacturers take their commitment to quality seriously, so they include a quality inspection phase in their production. This extra step ensures the pouches have the correct amount of nicotine and ingredients composition, and that no harmful contaminants are present.

4. Packaging

Finally, the pouches are sealed and placed into their packaging.

Manufacturers may use vacuum sealing, oxygen-absorbing packets, nitrogen flushing, or desiccants to help with this.

Packaging and labeling processes are both automated. But there’s still plenty of thought put into these steps!

Recently, biodegradable and sustainable packaging has been on the rise. Plus, manufacturers also choose eye-catching designs and convenient packaging (such as the option to store pouches in the lid).

5. Storage

Once the nicotine pouches are made, they are placed in cool, dry storage to maintain their freshness. This delays nicotine pouch expiration and ensures they’re delivered to customers in the best condition possible.

Do all Manufacturers Follow the Same Production Process?

There are many nicotine pouch manufacturers on the market, from Swedish Match to General Tobacco.

These companies all follow roughly the same process, but there are subtle differences. For instance, the choice between synthetic nicotine and tobacco-derived nicotine, or the selection of factory equipment.

Then there are firms pioneering unique nicotine pouch technology. One example is VOLT nicotine pouches, which use pearls technology (small balls of fibrous fillers that create a steady release of nicotine lasting up to an hour). This results in further differences in manufacturing processes.

Where are Nicotine Pouches Made?

The history of nicotine pouches goes back to Sweden, where they were introduced as a tobacco-free alternative to snus. ZYN from Swedish Match was the first major brand to emerge, but many more followed.

Nicotine pouches are now manufactured across the world, from Danish company The Ministry of Snus to Estonian brand NOIS. There are also nicotine pouch factories in the US and Asia.

Different countries may have different health and safety regulations.

Nicotine Pouches vs Snus Manufacturing

Despite myths about snus and nicotine pouches, the two products are very different.

Unlike nicotine pouches, snus contains tobacco — and this crucial difference results in a distinct manufacturing process.

Instead of deriving nicotine from plants or the lab, snus production involves fermenting, drying, and grinding tobacco.