Client Study - Nerudia

Nerudia started life as a fast-paced, e-cigarette start-up in Speke, Merseyside.

The company has since been acquired by Imperial Brands PLC.

How we helped

While Nerudia were experiencing rapid growth, setting up a large e-cigarette filling and innovation factory.,we assisted them in R&D and consulatancy. When they had an idea for a unique way of mixing e-liquid, they called us to help.

Project Info

Mixing e-liquids was proving a challenge for Nerudia as they had several stainless steel vessels that required cleaning and de-contaminating after each batch. When they found that mixing these liquids in a bag on a laboratory oscilating platform produced fantastic mix results, they decided to scale it up.

After receiving unfavourable results from tests on pre-available machinery they contacted us to help design and build the whole process. The innovation team at Nerudia had ideas of how the process should function, they just needed assistance to actually achieve a working solution.

Research and Design

Working with the Innovation team, we set about understanding how the process worked. It was clear that the first thing that was required was to actually prove that this mixing method would work when upscaled. We quickly designed and built a working testbed utilising standard, off the shelf parts that would allow the process to be tested in a controlled environment. This unit was not constructed to be a viable long-term machine, more a cost-effective development machine that would prove the effectiveness of process. Large plastic totes were lined with a plastic bag which was filled with e-liquid. This was then rotated using the eccentric machine bed to creating a wave within the bag which assisted the mixing, finding the perfect speed and process program in the process.

Initially, trials were completed on fifty litre batches and when they proved effective we decided to push the boundaries to two hundred and fifty litre batches, which also proved successful.

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Filling Station

50 Litre Prototype

250 Litre Tote

250 Litre Mixer

Display Features

Control System

HMI Control

Internal Mechanics

The Final Solution

Once we had proven the concept, Nerudia needed to create the final machine. As there was nothing on the market which fitted the process. a bespoke machine was required. Again working with the Innovation team, we created a complete system including mixing in a bag. This was more than just building a machine, a process was required. After many hours of research, the design was approved and we set about creating the final solution.

Utilising our in-house capabilities and working with our network of partner companies, we created the final, fully automated machine which also included data capture and print outs. The unit was fully stress tested, documented, CE certified and put into production and has produced thousands of tonnes of E-Liquid since.

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How else we helped Nerudia

During the initial start up phase of Nerudia,we assisted them with setting up the production suites and their infrastructure, providing consultancy to their team of engineers. We also provided consultancy services when purchasing machinery and setting up processes.

At this time, delivery times for new machines were proving problematic within their rapid growth, We designed and built several semi-automatic machines to allow production to carry on. These machines were later utilised for testing purposes.

Nerudia also had a small device Innovation department that was proving to be very successful, we assisted them in design and also creating various small prototype devices.

The company was eventually acquired by Imperial Brands PLC.

The photos below illustrate some of the other projects:

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