As a growing number of countries are banning disposable vapes, industry associations and manufacturers are working to establish more ambitious sustainability frameworks. Photo credit: SmileSmith25, CC4.0
As bans on disposable e-cigarettes take hold across a growing number of countries, manufacturers in the vaping sector are being forced to rethink product design to align with environmental regulations and changing consumer expectations. In response to mounting criticism over waste, fire hazards, and youth access, companies are adapting by developing devices that are more sustainable, recyclable and reusable—but meaningful transformation remains a work in progress.
While the industry initially focused on compliance, the regulatory pressure has accelerated efforts to offer more sustainable alternatives. Major players like Elf Bar, Geek Bar, and Lost Mary have responded quickly by launching rechargeable devices with refillable pods. These reusable products are designed to mimic the convenience and form factor of disposables while offering the possibility of extended use. However, many of these new products are currently undermined by poor refill pod availability. In a recent investigation by the Financial Times, several UK retailers were found to be selling rechargeable vape devices without offering compatible pods—effectively turning reusable products into single-use items. While these launches may satisfy the letter of new legislation, they risk falling short of its environmental intent.
At the same time, industry associations and manufacturers are working to establish more ambitious sustainability frameworks. In 2023, the UK Vaping Industry Association (UKVIA) published a 22-point environmental strategy titled “Greenprint for Sustainable Vaping.” The plan encourages a shift to refillable devices, the introduction of in-store recycling schemes and product labelling to guide consumers on proper disposal.
Promising product pilots
Manufacturers are beginning to explore design solutions that support these goals. Some are investing in modular construction, which allows consumers to disassemble and sort components such as batteries, plastics, and electronics. Others are experimenting with bio-based or biodegradable materials, and with simplified electronics to ease the environmental burden of manufacturing and disposal. The use of detachable batteries is also gaining traction, as this reduces fire hazards and improves the recyclability of discarded units.
Last year saw the introduction of several sustainable vape product pilots, among them Enviro Vape—a demonstration unit combining eco-plastic interiors with eco-paper exteriors—developed by ALD Group’s FRESOR Design Team. Designed for easy battery removal via a tear-along dotted line, the device disassembles into separable, recyclable components, according to the company. ALD promotes this as proof that fully biodegradable and recyclable vaping devices can be engineered with user-friendly design.
Also in 2024, Elf Bar unveiled a disposable concept e-cigarette prototype. Under the name R3, the product uses a corrugated paper structure and is designed to be manually disassembled into five parts: lithium battery, outer shell, airflow sensor, battery casing, nozzle, and nicotine filter. The disassembly of all parts allows the overall recycling rate of the product to be increased to 85%. According to the company, users can easily detach the outer shell along perforated lines and, after use, remove the battery from the base using a simple push-pull mechanism.
In April 2024, CCELL launched Eco Star, an all-in-one device built from PLA (corn-stover biopolymer). It features a removable lithium-ion battery and uses an aqueous fabrication process for ceramic heating elements—claimed to cut greenhouse gas emissions by 35%. CCELL positions the device as both biodegradable and ready for component recycling.
Regulatory environment tightens
These design efforts are taking place within an increasingly complex regulatory environment. In the UK and the EU, vape products are now subject to multiple directives intended to promote environmental responsibility. Under the Waste Electrical and Electronic Equipment (WEEE) framework, producers are required to provide systems for the collection and recycling of used devices. Extended Producer Responsibility (EPR) regulations oblige manufacturers and importers to finance the disposal of their products and report volumes accordingly.
Meanwhile, the forthcoming EU Packaging and Packaging Waste Regulation (PPWR 2025/40) introduces recyclability grading, mandates clearer labelling, and imposes limits on heavy metals in packaging. These rules, set to take effect between 2025 and 2028, are expected to shape how both packaging and devices themselves are constructed. Germany, for its part, is currently considering a nationwide ban on disposable vapes and in 2024 revised its Electrical and Electronic Equipment Act (ElektroG) to mandate the provision of retail vape return systems by mid-2026 at the latest.
However, despite the proliferation of rules and initiatives, significant obstacles remain. Vape devices are inherently difficult to recycle. Their compact size, mixed materials, nicotine residues and embedded electronics require specialized handling, which is not yet widely available in municipal waste systems.
Awareness among consumers is also limited. Many remain unaware of available take-back schemes, and some struggle to distinguish between refillable and disposable formats. Even when in-store collection is offered, uptake can be low. Retailers may also hesitate to participate in recycling initiatives due to space constraints and operational concerns.
Nevertheless, the industry appears to be at a turning point. The initial scramble to replace banned disposables with stopgap solutions appears to be giving way to more strategic planning around sustainability. While technical, logistical and behavioral barriers persist, the shift towards refillable, modular and eventually recyclable vape products is underway. For manufacturers and retailers, the message is increasingly clear: sustainability is not only a reputational imperative, but a practical requirement in markets where regulation is tightening, enforcement is expanding, and consumers are watching closely.