Where Do Wicks Come From?

A candle wick is a specially designed thread that is inserted into wax or fuel to provide the flame in candles and lamps. Wicks are a crucial component of candles, as they draw up melted wax to fuel the flame. They come in different materials, thicknesses and shapes for different candle types and applications. Wicks are what allow candles to burn, making light, ambiance and fragrance possible. Despite their importance, most people don’t think much about where wicks actually come from.

Definition of a Wick

A candle wick is a specially designed string that is inserted into candle wax to deliver fuel to the flame. The wick works through a property known as capillary action. Capillary action allows the wick to draw up liquid fuels such as melted wax via capillary suction. As the melted wax reaches the wick, it vaporizes and combusts with oxygen in the air to produce a flame. The candle wick essentially acts as a fuel pump to transport wax from the candle reservoir to the site of combustion at the tip of the wick. This drawing up of fuel sustains the flame and allows the candle to burn. Without a properly functioning wick, there would be no capillary action to move the melted wax, and the flame would be extinguished once the wax pool at the site of combustion had been consumed.

The key purposes of the candle wick are:

• Provide capillary suction to draw melted wax up to the flame
• Control the size and shape of the flame
• Influence how quickly the candle burns
• Affect smoke production

By engineering the wick material, diameter, and braiding, manufacturers can customize the wick properties for different types of candle wax and applications. The wick is a crucial functional element that enables controlled, sustained burning of candle wax.

History of Wick Origins

Wicks have been an essential component of candles and oil lamps throughout history. Early wicks were made from materials like rushes, animal hair, wood splints, and linen (History of Candlemaking – Candlewic: Candle Making). Rushlights, simple candles made by soaking rushes in animal fat, date back to ancient Egyptian and Roman times. In Europe during the Middle Ages, loose strands of flax were used as wicks which were inserted into wider containers filled with tallow or beeswax (Smith College Museum of Ancient Inventions: Candles). Through the 18th century, early candlewicks were made of materials like hemp, flax, or cotton that were twisted, braided, or woven together into a cord. The braided cotton wick, which burns cleanly and evenly, was invented in the early 19th century and helped drive the transition to kerosene lamps and paraffin wax candles (History – National Candle Association). This more sophisticated wick technology allowed candles to burn brighter and more efficiently.

Cotton Production

Cotton is the most commonly used material for manufacturing wicks today. Cotton has been cultivated for fabric production for thousands of years, with evidence of cotton cultivation dating back to ancient India, China, and the Middle East. Cotton remains an important crop grown around the world.

Cotton is cultivated in warm climates with long growing seasons. The top cotton producing countries today include India, China, the United States, Pakistan, and Brazil ^[1]. Cotton farming relies heavily on irrigation and in some cases can require heavy use of pesticides and fertilizers. However, there are increasing efforts to grow cotton more sustainably through organic and ecological farming practices ^[2].

Once harvested, cotton goes through a multi-step process to convert the raw cotton into thread and yarn for fabric production. This includes ginning to separate cotton fibers from seeds, carding and combing to align the fibers, spinning into yarn, and then weaving or knitting into fabric. The cotton fabric can then be used to manufacture wicks through cutting, braiding, and other techniques.

Wick Manufacturing

Wicks are made from cotton yarn through a two-stage process called waxing and cutting. The waxing stage involves taking raw cotton yarn and dipping it into a bath of liquefied wax multiple times. This coats the cotton fibers and binds them together. The now-stiff waxed cotton strands are then fed through a braiding machine that twists them into a flat or round braided wick shape. The wicks move through various rollers to control the braiding tightness and are finally cut to the desired length and width.

Wax helps bind the cotton fibers together and makes the wick rigid enough to stand upright in the melted wax or oil. The repeated dipping and drying allows wax to fully penetrate the cotton. The type of wax used depends on the intended candle or lamp fuel. Beeswax and paraffin wax are common. The braiding process gives wicks greater capillary action to absorb and transmit fuel. Wicks can be braided from as few as 3 to over 15 cotton strands. More strands increase wick diameter. Popular wick widths range from 1/16 inches for containers, up to 1/2 inch for pillars. Wick length depends on jar depth or candle diameter. This article provides more details on the wick manufacturing process.

Wick Companies

There are several major wick manufacturers around the world that produce wicks on a large commercial scale. Some of the top wick companies include:

Vedaoils – Based in India, Vedaoils is one of the largest wick manufacturers globally. They produce over 2000 tons of wicks per year across multiple manufacturing facilities in India. Vedaoils exports wicks to over 45 countries.

Atkins & Pearce – Founded in 1917, Atkins & Pearce is a major US-based wick producer located in Massachusetts. They manufacture over 500 styles of wicks for candles, incense, and more. Atkins & Pearce distributes wicks globally to wholesale and retail customers.

Fillmore Container – This California-based company produces wicks, candles, and containers. They manufacture over 400 styles of wicks using cotton, wood, and paper fibers. Fillmore exports wicks worldwide.

Other leading wick companies include Hemptique, Paramold Manufacturing, Candlewic, and Industrial Wick Manufacturing. Most major manufacturers are located in Asia, Europe, and North America where there is high demand for wicks.

Wick Testing

Wick testing is an important part of quality control for candle manufacturers. There are several key standards used to evaluate wick quality:

Burn rate – Wicks are tested to ensure they burn at an optimal rate, not too fast or too slow. According to the RAL Quality Standard for Candles, “The wick posture while burning is assessed visually. Wick shows curvature according to figure 2 or 3. Requirements met. Wick curvature deviates significantly from figure 2 or 3. Requirements not met.” (RAL-GZ 041)

Material purity – Wicks must be made from approved materials like cotton or paper fibers. Contaminants can alter the burn rate. ASTMF2417 states wicks should be “constructed from materials that are approved for use in wicks.” (ASTM F2417)

Capillary properties – Wicks rely on capillary action to draw fuel up to the flame. Testing allows selection of wicks with optimal capillary properties for the particular candle fuel. According to The Ultimate Quality Control Checklist for Scented Candles, inspect “If the wick is too small, the candle may not burn evenly.” (Quality Checklist)

Safety considerations – Proper wick testing minimizes common safety issues like tunneling, smoking, mushrooming, and sooting. Manufacturers must ensure wicks meet all applicable safety standards for the region where candles will be sold.

Wick Applications

Wicks have a variety of applications across many different industries. Some of the most common examples include:

Candles – Most candles utilize a simple braided or twisted cotton wick to draw wax up to the wick for burning. Specialty candle wicks are also available, like zinc or paper core wicks designed for different wax types.

Oil lamps – Similar to candles, oil lamps use wicks to draw fuel oil up to the burning tip. These wicks are often made from materials like cotton, wood, or paper that can absorb and transport the thick oil.

Stoves – Many camp stoves and oil burning lanterns use wicks to help control the flame. These sturdy wicks are often made from fiberglass or metal materials.

Vaping – The heating coils in electronic cigarettes function similarly to a wick, absorbing and vaporizing liquid efficiently.

Industrial – Large scale boilers and furnaces utilize specialized reinforced metal alloy wicks. These heavy-duty wicks are designed to operate at extreme temperatures. [1]

Science – NASA uses advanced nickel powder and screen mesh wicks on the ISS to transfer heat in zero gravity environments. [2]

Environmental Impacts

The environmental impacts of wick production largely stem from cotton farming. Cotton is a very water-intensive crop and accounts for 2.6% of global water usage. Chemical pesticides and fertilizers are also heavily used in cotton production, leading to soil erosion and water contamination. According to the Environmental Justice Foundation, cotton covers just 2.5% of the world’s cultivated land but accounts for 24% of global insecticide use and 11% of pesticide use (source).

Some companies are looking into more sustainable wick materials like hemp and wood. Hemp requires minimal water and no pesticides to grow, making it much more eco-friendly than cotton (source). Wooden wicks are also a renewable resource. However, cotton remains the most common wick material.

Recycling options for used wicks are limited. Most municipal recycling programs do not accept wicks due to their small size and cotton/paper composition. Some specialty candle recycling programs will collect used wicks to repurpose the cotton fibers, but these are not widely available (source). More research is needed into sustainable biodegradable wick materials and recycling infrastructure.

Future of Wick Technology

The future looks bright for innovations in wick materials and production methods. Companies are investing heavily in research to develop more sustainable and high-performance wicks. One area of focus is new fiber blends and coatings that can enhance wick properties like capillarity, rigidity, and durability. For example, Murata Manufacturing and Yasunaga have jointly developed a new type of wick using a proprietary blend of fibers and a special coating technology. This allows the wick to quickly absorb and release liquid while maintaining its shape over repeated uses.

Automation and advanced manufacturing techniques are also streamlining wick production. Machine vision systems and robotics are enabling faster, more precise wick assembly with less human input required. Companies like Yasunaga Cotton Wick now utilize automated machines that can measure, cut, twist, and braid cotton threads into finished wicks at very high speeds. This transition to automated wick making machines has increased production efficiency and quality consistency significantly.

Overall, innovations across materials science, automation, and manufacturing will support the continued evolution of wick technology. With improved performance, quality, and sustainability, the wicks of the future will likely find expanded applications across industries like healthcare, transportation, and consumer products.