Ben Carter
Candles have been manufactured for centuries, with ancient civilisations making them from animal fat, whale fat, and wax from seeds and insects. Today, candles are typically made from paraffin, a waxy material derived from petroleum, or beeswax. The manufacturing process involves three steps: preparing the wicking, preparing the wax base, and moulding or extruding the finished candles. Candle wax is heated and melted, and fragrances and dyes can be added before the mixture is poured into moulds or extruded through a die. The candles are then cooled and sent for packing. Modern candle manufacturing is a multi-billion dollar industry, with sales in the United States reaching approximately $3.2 billion annually in 2015.
| Characteristics | Values |
|---|---|
| Candle Manufacturing Steps | Preparation of the wicking, preparation of the wax base, and continuous molding or extrusion of the finished candles |
| Ancient Candle Ingredients | Animal fat, whale fat, wax from seeds and insects |
| Modern Candle Ingredients | Paraffin, beeswax, stearic acid, candelilla or carnauba waxes, cotton or linen wicks |
| Modern Candle Manufacturing Techniques | Melting wax, adding colors and scents, pouring into molds or jars, allowing to cool |
| Factors Affecting Candle Sales | Fragrance, seasonality (almost 1/3 of sales occur during holidays) |
| Popular Scents | French vanilla, cinnamon, mulberry |
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What You'll Learn
- Candle wax types: paraffin, beeswax, soy wax, palm wax, etc
- Candle wicks: made from cotton or linen, treated with chemicals
- Candle manufacturing process: melting wax, adding colour/scents, pouring into moulds
- Candle history: ancient Egyptians, Romans, Chinese used animal/insect fat
- Candle demand: sales peak during holidays, women buy 96% of candles
Candle wax types: paraffin, beeswax, soy wax, palm wax, etc
Candles are made by melting wax and pouring it into a mould. Colours and scents can be added to the wax while it is still liquid. The wax is then left to cool and harden, at which point the candle is ready for sale.
Different types of wax are used in candle-making, each with its own pros and cons. Paraffin wax, for example, is one of the most common and widely used candle waxes. It is synthetic, made from petroleum, coal, or shale oil, and is known for its opacity, consistent burn, and lack of odour. Paraffin is also versatile, affordable, and easy to use, with various melting points that make it suitable for different types of candles. However, it is not the most eco-friendly option, as it is derived from the oil industry and releases toxic soot and fumes when burned.
Beeswax is another popular option and is one of the oldest forms of candle wax. It is made by bees during the honey-making process, so while it is natural, it is not vegan. Beeswax has a subtly sweet natural scent and is known to burn brighter and longer without releasing toxic fumes. Its harder nature also makes it ideal for crafting freestanding pillar candles, although it is more expensive than other types of wax.
Soy wax is a more eco-friendly alternative to paraffin wax, and it offers a slow, steady burn that makes it great value. However, it does not hold fragrances as well as other waxes and can be temperamental to work with due to its sensitivity to temperature changes.
Coconut wax is a newer wax that is naturally sourced from coconut oil. It is vegan and known for its eco-friendliness, even burn, and smokeless and soot-free properties. However, it can be difficult to find as it is still new to the market.
Palm wax is similar to soy wax and is suitable for pillar and votive candles due to its hardness. Once dry, it creates unique crystal-like patterns on the surface. However, it is not the most eco-friendly option.
Other types of wax used in candle-making include bayberry wax, which is derived from the fruit of the bayberry bush and has a distinctive aroma, and rapeseed wax, which is able to retain fragrances and has a long burn time.
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Candle wicks: made from cotton or linen, treated with chemicals
Candle wicks are typically made from cotton or linen, though historically, a variety of natural materials were used. The use of cotton or linen wicks ensures a steady and bright flame, and these materials are also praised for their ecological and sustainable qualities. Cotton wicks are often braided by hand, and linen wicks are known for their resistance to deformation under thermal shock.
To improve their performance, cotton or linen wicks are treated with chemicals or inorganic salt solutions. This treatment ensures that the wick bends at a 90-degree angle when burning, allowing the end of the wick to remain in the outer mantle of the flame. If the wick is not treated, it will burn too quickly, causing the flame to be extinguished by the melted wax.
While natural materials like pine needles, wood splinters, and wool can be used as wicks, they often require chemical treatment to function effectively. For example, wooden wicks must be treated with chemicals to burn properly, and even then, they may not be suitable for all candle types.
Some candle makers prefer to use TCR-coated wicks, which are made from pure cotton interwoven with a twisted paper core and are not treated with chemicals or artificial substances. These wicks are well-suited for soy, rapeseed, and beeswax candles and are known for their superior burning capabilities.
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Candle manufacturing process: melting wax, adding colour/scents, pouring into moulds
The manufacturing of candles involves three steps: preparing the wicking, preparing the wax base, and continuous moulding or extrusion of the finished candles.
Firstly, the wick is prepared. This involves braiding cotton or linen into a high-grade wick, which is then treated with chemicals or inorganic salt solutions. This treatment ensures that the wick bends at a 90-degree angle when burning, allowing the end to remain in the flame's oxidizing zone, causing it to shorten naturally.
Next, the wax base is prepared. The wax is melted in a metal kettle over a direct flame or using the "Bain-Marie" method, where the wax is melted in a pan of boiling water. The wax is heated to a clear, near-liquid state at around 36 to 43 degrees Celsius. It is important not to overheat the wax, as this can cause carbon charring or affect the setting process. Once melted, the wax is carefully filtered to remove impurities that may interfere with burning.
At this stage, any desired colours, perfumes, or dyes can be added. The amount of fragrance added is important, as too much can cause "mushrooming", where there is an excess of wax fuel to burn. The type of fragrance oil used will also affect the size of the melt pool, which is the wax heated to the edge of its container, allowing the fragrance to diffuse without burning.
Finally, the liquid wax is poured into moulds. The amount of wax needed depends on the size and shape of the moulds, and it is generally recommended to double the amount of dry wax needed to fill the container. The wax is then left to cool and set, usually at room temperature or in a warm water bath, as cooling the wax too quickly can cause cracking. Once set, the candles are removed from the moulds and left to cure for optimal performance.
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Candle history: ancient Egyptians, Romans, Chinese used animal/insect fat
Candles have been used for thousands of years, with the earliest recorded use by the Ancient Egyptians. They created rushlights or torches by dipping reed piths in animal fat, but these lacked the wick, a characteristic of true candles. The Ancient Romans are credited with developing the wick candle, using papyrus and animal or insect fat, or beeswax. This invention was used for home lighting, travel, and religious rituals.
Other ancient civilisations such as the Chinese and Japanese also developed their own candles. The Chinese, for example, used wax made from insects and plants. The Northern and Southern Dynasties period, which began in 386 and lasted for over two centuries, saw the spread of candle usage among the Chinese people. The Tang Dynasty (618-907) is considered a high point in Chinese civilisation and also a period with numerous records about candle-making and usage.
During the Ming and Qing Dynasties, candles were widely used and had made their way into almost every Chinese household. Today, candles are still popular in China, particularly during holiday seasons. For example, on the final day of the Spring Festival (also known as the Lantern Festival), candles are lit outside houses to guide wayward spirits home. Candles are also used during the Mooncake Lampion Festival, the Hungry Ghost Festival, and the Mid-Autumn Festival. In addition, candles are a traditional part of Buddhist rituals, placed in front of shrines or statues of the Buddha as a mark of respect.
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Candle demand: sales peak during holidays, women buy 96% of candles
Candles are a popular gift choice, with 76% of candle purchasers viewing them as an appropriate present for the holidays. The Christmas/Holiday season accounts for approximately 35% of candle sales, with 38-40% of annual sales for some retailers occurring during this period. Seasonal and themed candles are particularly popular during the holidays, with consumers valuing functional and aesthetically pleasing products. The growing popularity of artistically designed candles has seen consumers embrace artisanal candles that enhance home decor beyond just light or scent.
The COVID-19 pandemic also contributed to a significant surge in candle sales globally, reflecting a growing demand for comfort and wellness products. Candles became a simple yet effective way to enhance living spaces and promote relaxation. The versatility and universal appeal of candles make them suitable for various occasions, from holidays to birthdays and anniversaries.
The candle market in the U.S. held a dominant share of 75% in 2024, with seasonal and festive demand being a major factor in boosting sales. Candles are a staple in holiday celebrations such as Christmas, Thanksgiving, and Halloween, where they are used for decoration and gifting. Pillar candles, which are larger, free-standing candles with long burn times and aesthetic appeal, have become increasingly popular due to their ability to burn for extended periods, making them ideal for events and gatherings.
The manufacturing process of candles involves three steps: preparation of the wicking, preparation of the wax base, and continuous molding or extrusion of the finished candles. Cotton or linen wicks are braided and treated with chemicals or inorganic salt solutions to ensure they burn at the correct angle. The wax base is typically made from paraffin, a waxy material derived from petroleum, which is melted and poured into a mold. Colours and scents can be added during this liquid stage, with the final product being ready for sale once the wax has cooled and set.
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Frequently asked questions
Modern candles are typically made from paraffin, a waxy substance derived from petroleum. Other materials used include beeswax, soy wax, palm wax, and blended varieties.
Candle manufacturing consists of three steps: preparation of the wicking, preparation of the wax base, and continuous molding or extrusion of the finished candles. The wick is made from cotton or linen and is treated with chemicals so that it burns evenly. The wax is heated and melted, and any fragrances or dyes are added at this stage. The molten wax is then poured into a mould and left to cool.
Fragrance is the number one factor affecting candle sales. The term 'scent throw' refers to the strength of a fragrance when the wax is solid (cold throw) and when it has been lit (hot throw).
