Tyler Brooks
The candle-making process starts with the selection of materials, which are chosen carefully to achieve different scents, burn temperatures, and effects. In the United States, commercial candles are typically made of paraffin, stearic acid, and beeswax, with added scent extracts. The manufacturing process consists of three steps: preparing the wicking, preparing the wax base, and continuous moulding or extrusion of the finished candles. First, the wax is heated and melted in large metal kettles, and any desired perfumes and dyes are added. Then, the molten wax is filtered to remove any impurities, after which the candles are moulded or extruded.
| Characteristics | Values |
|---|---|
| Candle Market Value in 2021 | USD $6.8 Billion |
| Candle Market Value in 2028 (predicted) | USD $9.9 Billion |
| Standard Commercial Candle Composition | 60% paraffin, 35% stearic acid, 5% beeswax |
| Candle Wicks | High-grade cotton or linen, braided |
| Wax Preparation | Wax is heated and melted, then filtered to remove impurities |
| Wax Additives | Scents, dyes, and stiffening wax |
| Candle Formation | Molding or extrusion |
| Molding Process | Wax is poured into molds with wicks, then cooled with water |
| Extrusion Process | Wax is forced through a heated die under pressure, forming around the wick |
| Shipping | Fast shipping is required to prevent damage to the candles |
| Pricing | 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
The first step in preparing the wax is to decide on the type of wax to be used. Commercial candles in the United States typically contain 60% paraffin, 35% stearic acid, and 5% beeswax. Other types of waxes used include candelilla and carnauba waxes, which are added to regulate the softening or melting point of the finished wax. Bayberry wax, derived from the fruit of the bayberry bush, is used for its distinctive aroma, especially during the holiday season.
Once the type of wax has been determined, the wax is heated and melted into a clear, near-liquid state in large metal kettles. It is important to avoid using direct flame to melt the wax, as this can cause the wax to become dark-coloured or contain small pieces of carbon char.
After the wax is melted, it undergoes a filtration process to remove any impurities that may interfere with the burning of the candle. This step ensures that the final product is of high quality. Even if the wax meets strict purity standards, many companies still choose to filter their wax.
At this stage, any desired perfumes and dyes can be added to the molten wax. Manufacturers often add scent extracts to give the candle a pleasant smell. Pumpkin and vanilla are popular choices in the United States, while beeswax candles are valued for their natural honey scent.
Once the wax is prepared with the desired additives, it is ready for the next steps in the candle-making process, which include preparing the wicking and moulding or extruding the finished candles.
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Wick preparation
The length of the wick should be slightly longer than the height of the candle. For a single wick, cut the string 3 inches longer than the candle's height, while for braided wicks, cut three equal pieces 4 inches longer than the candle's height. The wick material is typically cotton or linen, chosen for its ability to burn evenly and to curl so that its end remains in the flame's oxidizing zone.
To prepare the wicks, they are soaked in a solution to enhance their burning properties. One common solution is a mixture of Borax and salt, which helps the candle burn brighter and longer, while reducing ash and smoke. The wicks are soaked in this solution for 24 hours and then dried for 2-3 days. After drying, the wicks are dipped in molten candle wax to make them stiffer and easier to handle, as well as to help the flame catch more easily.
An alternative method for wick preparation is the dipping method, where the wick is repeatedly dipped into molten wax until the wax builds up to the desired thickness. This method was used historically and is still used for beeswax candles, along with the pouring method. In the pouring method, molten wax is poured over a suspended cotton wick, which is twirled simultaneously to ensure even coating.
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Moulding or extrusion
The use of moulds in candlemaking was introduced in the 14th century, but it wasn't until the 19th century that large-scale industrial manufacturing techniques were introduced for the mass production of moulded candles. Today, most candles are mass-produced from paraffin wax using a highly mechanised process.
In the moulding process, the wax is cooled to slightly above its melting point and poured into a moulding table located above the moulds. The wax then works its way into each mould, which have been pre-heated so that the wax flows evenly into them. After the wax is poured, a jacket around each mould is filled with cold water to speed up the solidification process. Once the wax has solidified, the finished candles are pulled upwards out of the moulds, allowing the wicks to again thread through the moulds in preparation for the next load. The wicks are then snipped, and excess wax is trimmed, collected and reused. This continuous moulding process can be used to make cylindrical, tapered or fluted candles, as long as they can be easily ejected from the mould.
An alternative to moulding is the extrusion process, in which crushed paraffin wax is forced through a heated steel die under extreme pressure. This produces a continuous length of candle, which is then cut into specific sizes. The tips of the candles are formed by rotation cutters, and the candles are sent to an automated packing machine. This method is particularly suitable for altar or pillar candles.
Another method is the pressing process, which uses an extrusion press to produce an endless strand of candle that is then mechanically cut into the desired length. This is also particularly suitable for altar or pillar candles.
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Cooling and removal
Once the candles have been moulded or extruded, they need to be cooled and removed from their casings. This is a critical stage in the process, as the candles are still vulnerable to damage at this point. To speed up the solidification process, a jacket around each mould is filled with cold water. This ensures the wax sets more quickly and helps to maintain the integrity of the shape.
After the wax has solidified, the candles are carefully extracted. They are pulled upwards out of their moulds, with the wicks threading through the moulds. This is an important step, as it prepares the moulds for the next batch of candles. The wicks are then cut to size, and any excess wax is trimmed, collected, and reused to minimise waste.
The cooling process is crucial to ensure the candles retain their shape and structure. If the candles are not cooled properly, they may melt or deform, rendering them useless. Thus, the use of cold water jackets is an efficient method to expedite solidification and maintain the desired shape of the candles.
The removal of the candles from the moulds must also be done with care. Any mishandling or rough handling can result in the candles breaking or cracking. Given that the wax is still relatively soft and pliable, even after solidification, gentle extraction is necessary to prevent damage to the final product.
After the candles have been successfully cooled and removed from their moulds, they undergo a final inspection to ensure they meet quality standards. This includes checking for any imperfections, cracks, or deformities that may have occurred during the cooling and removal process. Candles that pass this inspection are then packaged and shipped to retailers, ready to be displayed on store shelves.
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Trimming and reuse
Trimming the wick is an essential part of candle care. It helps to ensure a clean and even burn, prevents smoke and soot, and extends the life of the candle by up to 25%. As a candle burns, the wick starts to split and debris can form near the base. If left alone, this debris can be picked up by the flame, causing the candle to burn hotter and faster than intended.
To trim a wick correctly, extinguish the flame and let the candle cool down to room temperature. Then, use a wick trimmer or another cutting tool to trim the wick to a height of 1/4 inches above the wax. It is recommended to trim the wick at least every 4 hours of burn time.
In addition to trimming wicks, reusing candle wax is another way to extend the life of a candle. Instead of throwing away old candle wax, it can be melted down and repurposed into new candles. This can be done by gently melting the leftover wax in a double boiler or pot of water and then pouring it into a new container with a wick. Alternatively, the wax can be melted using an electric candle warmer and then poured into a new mold.
When reusing candle wax, it is important to thoroughly clean the container and remove any old labels or residue. It is also important to measure the container before purchasing a new wick to ensure an even burn. By reusing candle wax, individuals can enjoy their favorite scents for longer while also reducing waste.
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Frequently asked questions
Candles are made from wax, usually a mix of paraffin, stearic acid, and beeswax. The proportions of these vary depending on the type of candle. Wicks are typically made from cotton or linen, and sometimes contain wire.
The process involves three steps: preparing the wicking, preparing the wax base, and continuous moulding or extrusion of the finished candles. First, the wax is heated and melted in large kettles. It is then filtered, and dyes or perfumes are added. The molten wax is then poured into moulds with wicks, and the moulds are cooled with water to speed up solidification. Finally, the candles are removed from the moulds, excess wax is trimmed, and the wicks are snipped ready for the next batch.
Extrusion is an alternative method of forming candles without moulds. The wax is forced through a heated steel die under pressure, creating a continuous length of candle that must be cut into the correct sizes.
Candles must be packaged carefully to avoid damage during shipping. They are then sent via speed shipping to retailers, who place them on shelves for sale.
