UKCA Labeling & Packaging Requirements: Critical Guidelines for Vape Brands in 2025

LONDON, MAY 2025 – As the UK’s UKCA (UK Conformity Assessed) marking deadline approaches, proper labeling and packaging have emerged as make-or-break compliance factors for vaping products. Incorrect labeling accounts for 32% of MHRA non-compliance citations in 2025, highlighting the need for precise adherence to UK regulations. This guide breaks down key requirements, real-world pitfalls, and best practices to ensure your products meet UKCA standards.

1. Mandatory Labeling Elements for UKCA Compliance

All vaping devices and e-liquids sold in Great Britain must feature these non-negotiable label components:

a. UKCA Marking

• Placement: Affixed directly on the product (if feasible) or its immediate packaging (e.g., device boxes, e-liquid bottles).
• Size: Minimum height of 5mm; proportional scaling for larger packaging (logo must be legible and permanent).
• Notified Body Number: Include the certification body’s unique code (e.g., “BSI 0086” for products tested by BSI) next to the UKCA logo for traceability.

b. Health Warnings

• Standardized Text: Use the UK-mandated warning:
  “Contains nicotine – a highly addictive substance” (for nicotine-containing products).
  Non-nicotine products must state: “This product does not contain nicotine” if applicable.
• Visibility: Warnings must occupy at least 30% of the packaging surface (for e-liquids) or be prominently placed on device labels.

c. Product-Specific Information

• E-Liquids:
  • Nicotine concentration (e.g., “10mg/ml”) in bold font.
  • Volume (≤10ml for nicotine liquids, ≤50ml for non-nicotine) – UKCA retains the EU TPD’s 10ml limit for nicotine products.
  • Full ingredient list (INCI names), including propylene glycol, vegetable glycerin, and flavorings.
• Devices:
  • Model number, serial number (if applicable), and rated voltage (for rechargeable mods).
  • Child-resistant mechanism instructions (e.g., “Push & Twist to Open” for pod systems).

2. Packaging Compliance: Beyond Labels

a. Material Safety

• Child-Proof Packaging: All nicotine-containing products must use packaging compliant with EN 12387:2015 (difficult for children under 5 to open but easy for adults).
• Environmental Standards: While not explicitly UKCA-mandated, the UK’s 2025 Packaging Waste Regulations encourage recyclable materials (e.g., FSC-certified cardboard), which can enhance brand sustainability credentials.

b. Market-Specific Adjustments

• Northern Ireland: Products sold here require both UKCA and CE marking due to EU single market alignment. Dual labeling is mandatory to avoid customs delays.
• Language: Labels must be in English; bilingual packaging (e.g., English + Welsh) is permitted but not required.

c. Prohibited Claims

• Avoid phrases like:
  • “Safer than cigarettes” (misleading health comparisons).
  • “Helps quit smoking” (unauthorized medical claims without MHRA approval).
  • “100% natural flavors” (unless proven via toxicological testing).

3. Case Study: How Labeling Errors Cost a Brand £1.5M

In April 2025, UK customs seized 80,000 disposable vapes from VapeGlow UK due to three critical labeling flaws:

1. UKCA Logo Oversight: The logo was printed in light gray (non-permanent) and lacked the notified body number, making certification verification impossible.
2. Warning Text Omission: The packaging omitted the legally required nicotine addiction warning, relying instead on a generic “Use responsibly” message.
3. Volume Mislabeling: A 15ml nicotine e-liquid was falsely labeled as “10ml,” violating the 10ml UKCA/TPD cap.

The penalty: a £1.5 million fine and a 6-month ban on importing to the UK. This case underscores the need for rigorous pre-compliance checks.

4. Best Practices for Labeling & Packaging

a. Use Official Templates

• Download free MHRA-approved label templates from the UK Government portal, which include correct font sizes, warning placements, and logo specs.
• For dual-market products, create a “labeling matrix” to track EU (CE/TPD) vs. UK (UKCA) requirements (e.g., EU requires pictorial health warnings, while the UK mandates text-only).

b. Conduct Pre-Production Audits

• Partner with a third-party compliance firm (e.g., Bureau Veritas) to review label proofs for:
  • UKCA logo compliance (size, color, permanence).
  • Ingredient list accuracy (matching test reports from notified bodies).
  • Warning text exactness (no paraphrasing of mandated phrases).

c. Leverage Technology for Traceability

• Embed QR codes on packaging linking to:
  • UKCA certification details (validity, notified body).
  • Safety data sheets (SDS) for e-liquid ingredients.
  • Recycling instructions (boosting consumer trust and sustainability scores).

5. FAQ: Common Labeling Quirks

• Q: Can I use the EU TPD warning on UK packaging?
  A: No. UK law requires the specific phrase: “Contains nicotine – a highly addictive substance”. EU warnings like “Nicotine is addictive” are non-compliant.

• Q: What if my device is too small for the UKCA logo?
  A: Place the logo on the immediate packaging instead (e.g., the box), but ensure the product itself has a unique identifier (model number) linking to the DoC.

• Q: Do non-nicotine e-liquids need child-proof packaging?
  A: Yes. UKCA mandates child-resistant packaging for all e-liquids, regardless of nicotine content, to prevent accidental ingestion.

6. Expert Insight: “Labeling is the First Line of Compliance”

“Many brands overlook labeling’s legal precision,” says Sarah Hughes, regulatory consultant at Compliance First Group. “A single typo in the warning text or a missing notified body number can halt your entire shipment. Invest in labeling software that auto-checks UKCA rules—costs start at £500/month but save 10x in avoidable fines.”

Key Resources for Compliance

• Child-Proof Packaging Suppliers List: Approved Vendors
• UKCA Label Generator Tool: Free to Use

By prioritizing labeling and packaging compliance, manufacturers can avoid costly delays, maintain consumer trust, and thrive in the £2.8 billion UK vape market. Remember: UKCA marking is not just a logo—it’s your product’s passport to Great Britain.

This article is for informational purposes.