How Do They Make Wicks?
A wick is a cord or string embedded inside a candle, oil lamp, or other fuel source that conveys the fuel to the flame. The wick’s primary purpose is to deliver fuel to the flame in a slow, controlled manner so that the flame burns steadily without going out or flaring up. The wick absorbs and transports fuel by capillary action up through the fibers of the wick to the flame. This creates a self-sustaining reaction where the heat of the flame melts the fuel which is then delivered up the wick until consumed by the flame. Properly sized and maintained wicks are essential for even, efficient fuel burning and flame consistency.
Materials Used
There are several common materials used to make candle wicks, including cotton, wood, and paper.
Cotton is one of the most popular wick materials due to its versatility and ability to bend without breaking. Quality cotton threads are soft, absorbent, and create a bright flame. Different types of cotton wicks work best for different wax formulas.
Wooden wicks contain wood fibers that help improve wax flow to the top of the wick. They create a pleasant crackling sound when burning and can be coated with zinc or tin to prolong their use. Popular types of wood for wicks include bamboo and wooden chips.
Paper wicks don’t require priming before use and are economical. However, they don’t last as long as cotton or wood wicks. Common paper materials for wicks include flat braided paper and square braided paper fibers.1
Cotton Wicks
Cotton is the most common material used to make wicks. To transform cotton into wick yarn, the raw cotton first goes through a cleaning process to remove any debris, stems, and seeds. The cotton fibers are then carded to align the fibers and form a continuous web or sliver. The sliver is drawn into roving, which further aligns the fibers and condenses them into a soft rope. This roving is then spun into yarn on spinning frames. The spun yarn can be plied with multiple strands twisted together to form thicker wick yarns. These cotton yarns are then wound onto spools or cones for wick production[1].
Some key properties that make cotton an ideal wick material are its absorbency, capillarity, and low conductivity. The fine structure of cotton fiber enables it to effectively soak up and transport melted wax or oil via capillary action. The natural fibers are also soft, flexible, and resilient, allowing cotton wicks to bend without breaking easily[2].
Wooden Wicks
Wooden wicks are made from softwoods like maple, pine, and cedar (source). The wood is cut into thin strips and shaped into wicks. To prepare the wood for burning, it is baked at high temperatures which removes moisture, sap, and resins. This process also makes the wood rigid so it retains its shape. The rigid wood burns slowly and provides the signature crackling sound as pockets of sap vaporize when heated.
The shaping process involves cutting wood into narrow strips using specialty blades, then wrapping the strips around forms to create round or square wick shapes. The rigid wooden wicks can then be coated in wax to help retain their structure. Quality control checks are performed to ensure correct diameter, integrity of the wrap, and straightness of the wick before packaging.
Paper Wicks
Paper can also be used to create candle wicks. Certain types of paper work better than others for wicks due to properties like thickness, absorption, and flammability. Some common papers used for candle wicks include:
Tissue Paper – Very thin and lightweight tissue paper can be tightly rolled or braided to create a wick. The thinness allows the wick to curl and bend as it burns.1
Kraft Paper – Kraft paper is made from chemical pulp and is more absorbent than tissue paper. It can be folded and twisted to make sturdy wicks.1
Newspaper – Recycled newspaper can be shredded and rolled tightly to create an economical wick option. The wood pulp fibers provide good capillary action.1
The key considerations are thickness, which affects how cleanly the wick burns, absorbency to draw fuel up, and fiber content for structural integrity when saturated with wax or oil. With testing, many types of paper can be adapted for homemade candle wicks.
Wick Braiding
Wick braiding is the process of intertwining multiple strands of wick material to create a thicker, more rigid wick. The most common braiding technique used is a 3-strand braid, where 3 individual wicks are braided together (Source). This creates a strong, tightly wound wick that holds its shape well. More complex braids using 4, 5 or more strands are also possible for specialty wick applications. The tension and tightness of the braiding is important, as loose braids can unravel or bend out of shape. Wicks may be braided by hand or by specialized braiding machinery for mass production.
The braiding process allows multiple thinner wicks to be combined into one larger wick, combining strength and capillary properties. It also reduces the risk of loose fibers coming free from the wick. High quality wick braiding results in a smooth, cylindrical wick without gaps, lumps or imperfections. Consistent braiding improves wick durability, while tightly compressed braids maximize rigidity.
Wick Coating
The coating applied to wicks is an important factor in candlemaking. Coatings help stabilize the wick and control the burn rate. According to research, “coating materials for the evaporator section” help improve performance (https://www.academia.edu/9958432/An_experimental_study_of_the_utilization_of_heat_pipes_for_solar_water_heaters).
Coatings are typically applied by dipping or soaking the wick material into a solution. Common coating materials include wax, zinc stearate, and Vybar. The coating fills in gaps in the braided fibers and binds them together. This prevents loose strands from breaking off and distorting the flame.
Coatings also regulate wick combustion. Materials like zinc stearate slow down the burn rate by forming an ash barrier on the wick as it melts. This prevents the wick from swelling and controls the size of the flame. Properly coated wicks burn evenly from top to bottom without flaring up.
Shaping
Proper shaping of the wick is crucial for optimal candle performance. After the wick has been braided or coated, it needs to be cut to the proper height for the candle container being used.
There are a few methods for cutting candle wicks to size:
Using a wick trimmer or other cutting tool, the wick should be trimmed to 1⁄4 inch above the wax according to experts at Courtney’s Candles (https://www.courtneyscandles.com/pages/wick-trimming-101). Allow the blades to catch any wick debris.
The height of the wick above the wax depends on the diameter of the container according to Lonestar Candle Supply (https://lonestarcandlesupply.com/guide-to-wicking/). For example, use a shorter wick for smaller containers and a longer wick for larger containers.
It’s important not to cut the wick too short or too long. An improperly trimmed wick can lead to poor wax pooling, tunneling, or smoking.
Quality Testing
Before wicks are shipped to customers, they undergo rigorous quality testing to ensure they meet performance standards. Some key parameters tested include:
- Burn rate – Wicks are tested to verify they burn at an ideal, steady rate, neither too fast nor too slow.
- Wick thickness and shape – The thickness and shape of the braided wick is measured at multiple points to ensure consistency.
- Ash content – Wicks are burned and the amount of ash residue left behind is measured. Quality wicks will have minimal ash.
- Soot testing – Wicks are burned in controlled conditions while the amount of soot released is quantified. High-quality wicks release little soot.
- Fragrance throw – For scented candles, wicks are evaluated to confirm they enhance fragrance diffusion when burned.
- Flame height – The height of the flame is observed to make sure the wick produces the proper size flame for the candle.
In addition to lab testing, wicks may be hand tested by production quality technicians who visually inspect them for defects and burning characteristics (Quality Control Technician – Wick’s Pies, Inc. | Winchester, IN). Only wicks that pass all quality control checks are approved for customer shipments.
Applications
Wicks have many applications, but some of the most common are candles, oil lamps, and incense burners. In candles and oil lamps, the wick is a critical component that brings fuel to the flame through capillary action. As the fuel vaporizes, it moves up the wick and feeds the flame. Quality wicks are essential for even, reliable burning. Different wick materials and braiding patterns optimize performance based on the type of wax or oil used. Cotton, for example, is commonly used for paraffin candle wicks. Wooden wicks create an audible crackling and are popular for soy candles. Wicks also disperse fragrance in scented candles. In incense burners, the wick helps control the rate of burning for incense sticks or cones. Testing wick quality helps ensure proper burning and safety. Overall, wicks enable controlled, consistent burning across many fire-based applications.
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