Tyler Brooks
Candles are one of the few universal goods that almost everyone can benefit from. The global candle market was valued at USD $6.8 billion in 2021 and is expected to reach USD $9.9 billion by 2028. The candle-making process starts with the selection of materials, which are carefully chosen for their scents, burn temperatures, and effects. The manufacturing process consists of three steps: preparation of the wicking, preparation of the wax base, and continuous moulding or extrusion of the finished candles.
| Characteristics | Values |
|---|---|
| Materials | Paraffin, stearic acid, beeswax, candelilla wax, carnauba wax, bayberry wax, cotton or linen wicks |
| Process | 1. Preparation of wicking, wax base, and moulding/extrusion |
| 2. Heating wax in metal kettles | |
| 3. Filtering wax to remove impurities | |
| 4. Adding perfumes and dyes | |
| 5. Pouring wax into moulds with wicks | |
| 6. Speeding up solidification with cold water | |
| 7. Removing candles from moulds, trimming excess wax | |
| 8. Cutting extruded candles into specific sizes | |
| Market Price | Mass market: $7 to $11 |
| Mid-market: $13 to $18 | |
| High-end: $19 to $28+ |
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What You'll Learn
- Wax preparation: melting, filtering, and adding scents/dyes
- Wicking: braiding cotton/linen, treating with chemicals, and feeding into moulds
- Moulding: pouring wax, cooling, and removing candles
- Trimming: cutting wicks, collecting excess wax, and re-using
- Extrusion: forcing wax through a die, cutting continuous lengths, and creating custom shapes
Wax preparation: melting, filtering, and adding scents/dyes
Wax preparation is a crucial step in the candle-making process. It involves melting the chosen waxes, filtering the molten wax to remove impurities, and adding any desired scents or dyes to create a high-quality finished product.
The first step in wax preparation is melting the wax. The wax is heated and melted in large metal kettles until it reaches a clear, near-liquid state. It is important to avoid using direct flame to melt the wax, as this can cause the wax to become darkened or contain small pieces of carbon char.
Once the wax is melted, it undergoes a careful filtration process to ensure purity and smooth burning. This step removes any impurities that may interfere with the candle's burning process. Even though the wax may arrive at the manufacturer adhering to strict purity standards, many companies still choose to filter the wax again to guarantee its quality.
After filtration, the wax is ready for the addition of scents and dyes. Manufacturers often mix different types of wax together to create stronger candles with higher melting points. For example, standard commercial candles in the United States typically contain a mixture of paraffin, stearic acid, and beeswax. During this stage, manufacturers may also add small amounts of other waxes, such as candelilla or carnauba wax, to regulate the softening or melting point of the final product.
To create scented candles, manufacturers add scent extracts to the wax mixture. The choice of scent is an important part of the candle-making process, with popular options including pumpkin, vanilla, and the natural honey scent of beeswax. During the holiday season, bayberry wax, derived from the fruit of the bayberry bush, is a popular choice for its distinctive aroma.
Finally, dyes may be added to the wax to create candles in a variety of colours. Once the wax is prepared with the desired scent and colour, it is ready for the next steps in the candle-making process, which include preparing the wick and moulding or extruding the finished candles.
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Wicking: braiding cotton/linen, treating with chemicals, and feeding into moulds
Wicks are made from high-grade cotton or linen, braided together so that they burn in one direction and curl, ensuring the end remains in the candle flame's oxidizing zone for even burning. Wire-core wicks are often used. The wicking is then treated with chemicals or inorganic salt solutions so that they bend at a 90-degree angle when burning. This treatment is essential to ensure the wick doesn't burn too quickly and get extinguished by the melted wax.
Once the wicking is prepared, it is fed into the centre of the mould, with the help of a wick bobbin. This ensures that the wax forms around the wick. After the wax is poured, a jacket around each mould is filled with cold water to speed up the solidification process. The wicks are then snipped, and the candles are pulled upwards out of the moulds, allowing the wicks to thread through the moulds again, ready for the next batch.
The continuous moulding process is used for cylindrical, tapered, or fluted candles, as long as they can be easily ejected from the mould. An alternative method is extrusion, where the wax is forced through a heated steel die under pressure, and the wax consolidates around the wick. Unlike moulding, this process creates a continuous length of the candle, which must then be cut into specific sizes.
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Moulding: pouring wax, cooling, and removing candles
The first step in moulding candles is to heat and melt the wax into a clear, near-liquid state in large metal kettles. Direct flame should be avoided as it can cause discolouration or the formation of carbon char within the wax. Once the wax is molten, it is carefully filtered to remove any impurities that may interfere with the burning process. Manufacturers often add dyes and perfumes at this stage.
Next, the liquid wax is poured into the moulds, which have a wick already in place. A jacket around each mould is then filled with cold water to speed up the solidification process. The wicks are threaded through the moulds, allowing for continuous moulding. Once the wax has cooled and solidified, the candles are removed from the moulds. The wicks are snipped, and excess wax is trimmed, collected, and reused.
The moulding process is used to create candles with a cylindrical, tapered, or fluted shape. It is also possible to use extrusion to form candles, which involves forcing the wax through a die of the desired shape. However, unlike moulding, extrusion creates a continuous length of candle that must be cut into the proper sizes.
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Trimming: cutting wicks, collecting excess wax, and re-using
Trimming is an important step in the candle-making process. Once the wax has been poured and the candles have solidified, they are removed from their moulds. At this stage, the wicks are cut to the appropriate length, and any excess wax is collected. This excess wax is then reused, ensuring that there is no waste in the production process. This step is crucial for maintaining the quality of the candle and its appearance.
The wicks are typically made of high-grade cotton or linen, chosen for their ability to burn evenly and intensely. They are braided or woven to ensure they burn in one direction and curl back into the candle's flame, allowing for a consistent burn. The trimming process ensures that the wick remains at the correct length for optimal burning.
During the trimming process, it is essential to collect the excess wax that is trimmed from the candle. This wax can then be reused in the candle-making process, reducing waste and ensuring cost-effectiveness. The collection process involves gathering the excess wax and melting it down again to be poured into new moulds.
Factories may have specific procedures for collecting and reusing wax. For example, they may use special tools or equipment to efficiently collect the excess wax, and they may have specific melting and filtering processes to ensure the reused wax is of the same quality as new wax.
The reuse of excess wax is an important aspect of sustainable candle-making. By reusing the wax, factories can reduce their environmental impact, conserve resources, and create a more circular production process. This practice not only reduces waste but also allows for cost savings and the optimisation of resources.
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Extrusion: forcing wax through a die, cutting continuous lengths, and creating custom shapes
Extrusion is a method of candle-making that involves forcing wax through a die under extreme pressure to create continuous lengths with custom shapes. This process is an alternative to the traditional moulding method, which uses cylindrical, tapered, or fluted moulds. In extrusion, crushed paraffin wax is heated and forced through a heated steel die, resulting in a continuous length of candle that must be cut into specific sizes.
The first step in the extrusion process is the preparation of the wick. Cotton or linen wicks are braided and treated with chemicals or inorganic salt solutions. This treatment ensures that the wick bends at a 90-degree angle when burning, allowing it to remain in the outer mantle of the flame and burn at a controlled rate. Untreated wicks would burn too quickly and be extinguished by the melted wax.
The wax itself undergoes a similar preparation process. The wax is heated and melted into a clear, near-liquid state in large metal kettles. Direct flame heating is avoided as it can discolour the wax or leave small pieces of carbon char. The molten wax is then carefully filtered to remove impurities that may interfere with burning. At this stage, desired perfumes and dyes are added.
Once the wick and wax are prepared, they are combined in the extrusion process. The wick is fed into the centre of the die through a wick bobbin, ensuring that the wax forms around it. As the wax is forced through the die, it consolidates around the wick, creating a continuous length of candle with a custom shape. The extruded candle is then cut into proper sizes, and the excess wax is trimmed, collected, and reused.
The extrusion method allows for the creation of unique candle shapes and designs that may not be possible with traditional moulding techniques. It also enables the production of longer, continuous candles that can be cut to specific sizes, providing flexibility in the manufacturing process.
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Frequently asked questions
Candles are made of wax, usually a mix of paraffin, stearic acid, and beeswax. The proportions of these substances may vary, and some candles may also contain candelilla or carnauba waxes.
The candle-making process consists of three steps: preparation of the wicking, preparation of the wax base, and continuous molding or extrusion of the finished candles. First, the wax is heated and melted in large metal kettles. It is then filtered to remove any impurities, and any desired perfumes and dyes are added. The molten wax is then poured into molds with wicks, and the molds are cooled to speed up the solidification process. Finally, the candles are removed from the molds, and any excess wax is trimmed and reused.
Wicks are typically made of high-grade cotton or linen, woven or braided so that they burn in one direction. They are treated with chemicals or inorganic salt solutions to ensure they burn at a suitable rate and angle.
The type of wax used in candles varies and depends on the desired properties of the candle. Paraffin wax is a common ingredient due to its high melting point, while beeswax is popular for its natural honey scent. Bayberry wax, derived from the fruit of the bayberry bush, is often used during the holiday season for its distinctive aroma. Other types of wax include candelilla and carnauba wax, which are used to regulate the melting point of the finished candle.
