Joseph Hart 11 February 2025

 

British American Tobacco (BAT) recently announced a new line of its popular VELO nicotine pouch called VELO Plus. Slated for release this year, these pouches will use synthetic nicotine instead of nicotine extract from tobacco plants.

While this generated form of nicotine is frequently used in vape juice —especially among smaller manufacturers —it’s one of the first examples of a Big Tobacco brand using synthetic nicotine for its pouches.

So, what is synthetic nicotine, how is it different from natural nicotine, and should we expect to see more brands use this lab-generated product in the future?

What is synthetic nicotine?

Synthetic nicotine is a lab-grown form of nicotine. Instead of being extracted from tobacco leaf, synthetic nicotine is made via complex chemical processes in a controlled environment to create a molecularly similar product.

Bodies like the Truth Initiative or the American Lung Association claim that synthetic nicotine is a ploy to circumnavigate legislation about tobacco products. However, it was first synthesised around 120 years ago.

How is synthetic nicotine made?

Traditional nicotine is extracted from tobacco leaves. However, the synthetic form of the compound is created in a lab using chemical synthesis. Here’s a brief description of how that works.

Step 1: The process begins with a chemical precursor like ethyl nicotinate.

Step 2: Compounds like N-vinyl-2-pyrrolidinone are added to the precursor. This step forms intermediates such as myosmine, which is then reduced into nornicotine.

Step 3: Through methylation, nornicotine becomes nicotine. Depending on the method, nicotine is either a racemic of S-nicotine and R-nicotine or pure S-nicotine.

It’s important to note that this process has a few variations, which are largely due to patents or proprietary techniques used by particular manufacturers. Despite the different approaches, the goal is the same: to replicate the molecular structure of naturally occurring nicotine without involving tobacco plants.

What is the difference between synthetic and natural nicotine?

The chemical formula for nicotine is C10H14N2, which means:

  • C: Carbon – 10 atoms
  • H: Hydrogen – 14 atoms
  • N: Nitrogen – 2 atoms

The formula for both natural and synthetic nicotine is the same. However, there are some notable differences that result from the different production processes, namely:

  • Synthetic nicotine can result in a purer product, free from residual tobacco plants like nitrosamines.
  • The same absence of impurities means synthetic nicotine lacks tobacco flavourings, which makes it ideal for products like pouches and vape liquids.
  • Natural nicotine is more than 99% S-nicotine, while synthetic is typically a mix of S-nicotine and R-nicotine.

Is synthetic nicotine good for the environment?

Tobacco control groups occasionally lean on the argument that tobacco cultivation is devastating for the environment. While this line of thinking is too reductive, it’s worth considering whether synthetic nicotine can provide an alternative to traditional production methods.

So, how do natural and synthetic nicotine manufacturing processes compare in terms of environmental impact?

Positives

  • Synthetic nicotine is lab-grown, so it doesn’t require vast tracts of land, fertiliser, deforestation, and so on.
  • Cultivating and curing natural tobacco involves carbon dioxide emissions. Synthetic nicotine has a lighter footprint, which can reduce the overall impact of vapes and pouches.
  • Lab-grown nicotine is amenable to sustainable practices that would not involve intensive farming that could affect the land.

Negatives

  • Synthesising nicotine is energy-intensive.
  • Synthetic nicotine is more expensive to produce, which may harm widespread adoption or the inclusion of smaller producers.

Final thoughts

Synthetic nicotine offers an intriguing alternative to traditional nicotine production. Instead of being extracted from tobacco, this lab-grown nicotine is made from chemical precursors. As manufacturers look for new, low-impact ways to make nicotine, expect to see more synthetic nicotine used in products like vape juice and nicotine pouches.