How and Where Are Zyns Made? Manufacturing Insights

Zyn nicotine pouches have captured a major share of the tobacco alternatives market. This guide explains their manufacturing locations and how production has evolved.

These small white pouches deliver nicotine when placed between the upper lip and gum. Unlike traditional products, they contain no tobacco leaf or plant material—a fact that has many consumers curious about their production process.

In this guide, we'll cover:

• Zyn’s Manufacturing locations in Sweden and the United States

• The company’s wnership structure

• Production facility details

• Its nicotine sourcing methods

• Manufacturing technology behind Zyn pouches.

Zyn Manufacturing Locations and Facilities

Where Are ZYN Pouches Manufactured?

Zyn's primary manufacturing facility is located in the United States, though the product was first developed in Sweden. From 2017 to 2019, Swedish Match expanded its U.S. factory in Owensboro, Kentucky to meet America's growing demand for Zyn pouches.

The company invested $115 million in this expansion. When the expanded Kentucky facility opened in May 2019, it became a dedicated production center for Zyn products in the U.S. market. This strategic manufacturing location eliminated most imports from Sweden and reduced transportation costs.

Manufacturing Timeline and Expansion

Here's how Zyn's production has evolved:

• 2016: Initial production launches in Sweden, with simultaneous market entry in Sweden and limited U.S. regions (starting in Colorado)

• 2017-2019: Major expansion of the Owensboro, Kentucky facility to meet growing U.S. demand

• May 2019: Expanded Kentucky factory opens as Zyn's primary North American production hub

• November 2022: Philip Morris International (PMI) acquires Swedish Match, potentially influencing future manufacturing decisions

The Kentucky facility expansion stands as one of the largest investments in tobacco-alternative manufacturing in recent years.

Who Manufactures Zyns?

Swedish Match created and manufactures Zyn nicotine pouches, leveraging its expertise in snus production to develop this tobacco-free alternative. The company introduced Zyn in response to changing consumer preferences and stricter regulations on traditional tobacco products.

In November 2022, Philip Morris International (PMI) acquired Swedish Match, integrating Zyn into one of the world's largest tobacco companies. This acquisition aligned with Philip Morris's "smoke-free future" vision, adding Zyn to a portfolio that includes Iqos heated tobacco and Veev vaping products.

How Zyn Pouches Are Made

Zyn pouches are made through a specialized manufacturing process that sets them apart from traditional tobacco products. The process follows these key steps:

1. Base material preparation: Microcrystalline cellulose is processed into a consistent form suitable for pouches

2. Nicotine incorporation: Precise amounts of nicotine salt are added to the base material according to desired product strength

3. Flavor addition: Flavors (e. g. cool mint, wintergreen, peppermint) and sweeteners are blended into the mixture

4. Pouch formation: The mixture is portioned and sealed in small, white pouches for oral use

5. Packaging: The pouches are packed in labeled cans indicating strength and flavor

This manufacturing process is designed to ensure consistent quality and nicotine delivery across all production runs.

The Source of Zyn Nicotine

Zyn pouches are marketed as "tobacco-free" nicotine products that differ from traditional snus and other smokeless tobacco products. Instead of tobacco leaf or fibers, the pouches use microcrystalline cellulose as a base material with nicotine salt as the active ingredient.

The formula incorporates flavors such as spearmint, sweeteners, and additives to enhance the user experience while maintaining its tobacco-free status. Studies show that Zyn delivers nicotine more efficiently than traditional products. When compared to conventional snus products like 8 mg General (32% extraction), Zyn products achieve higher nicotine extraction rates (56% and 59%).

As a result, Zyn pouches can provide similar or stronger nicotine effects despite containing less total nicotine than tobacco products.

Key Manufacturing Facts:

• Primary Factory: Owensboro, Kentucky, USA

• Factory Expansion: $115 million investment (2017-2019)

• Original Production: Sweden (2016)

• Current Production Capacity: Supports over 125 million cans annually

• Owner/Manufacturer: Swedish Match (acquired by Philip Morris International in 2022)

• Production Timeline: Began in Sweden (2016) → Kentucky expansion (2019) → Continued growth under Philip Morris (2022-present)

What Are ZYN Pouches?

ZYN pouches are tobacco-free nicotine delivery systems. They combine microcrystalline cellulose (a food-grade plant material) with nicotine salt, along with flavors, sweeteners, and stabilizers.

Users place these small pouches between their upper lip and gum, where the nicotine and flavors are absorbed directly through the mouth tissues into the bloodstream—no ingestion or inhalation needed.

ZYN offers various nicotine strengths and flavors to suit different preferences. Some products are marketed as "unflavored," such as "Smooth" and "Chill," helping the brand navigate markets with flavor restrictions. However, even these unflavored varieties provide distinct sensory experiences—"Chill," for instance, offers "a slight sweetness and an actual chilling sensation".

Are Zyns Bad for You?

While our focus is on manufacturing, understanding the health implications provides important context for Zyn's production choices.

Nicotine binds to acetylcholine receptors in the brain, triggering the release of dopamine, norepinephrine, and serotonin. This mechanism explains both the temporary mental benefits users experience and the potential for dependence.

Adolescents are particularly vulnerable since nicotine can affect brain development. Research indicates that early nicotine exposure may increase the risk of substance use disorders later in life.

For oral health, Zyn pouches release alkaline substances when in contact with gums, disrupting the mouth's natural bacterial balance. Regular use may lead to gum recession and tissue changes.

Though Zyn is free of tobacco-specific nitrosamines, its flavor compounds may impact gum tissue. Users have reported digestive issues such as constipation, nausea, or diarrhea.

The cardiovascular system is also affected as nicotine activates the sympathetic nervous system, increasing heart rate and blood pressure. Research indicates that long-term nicotine use may raise the risk of hypertension and cause metabolic changes, even without tobacco use. Thus, while Zyn eliminates many harmful components of traditional tobacco, it still carries health risks.

Comparing Zyn to Other Nicotine Products

ZYN's nicotine delivery system sets it apart from traditional tobacco products, with studies showing unique efficiency patterns.

Total nicotine exposure measurements (AUCinf) reveal that ZYN 3 mg delivers 27% less nicotine than 8 mg General snus, while ZYN 6 mg delivers 34% more. ZYN 8 mg matches the nicotine delivery of Longhorn Natural 18 mg moist snuff, despite containing less than half the nicotine. The secret lies in extraction efficiency: ZYN 8 mg extracts 50% of its nicotine, significantly outperforming Longhorn Natural's 19% and General 2 × 8 mg snus pouches' 33%.

Why Have Zyn Pouches Taken Off in the US?

Zyn has experienced dramatic growth in the United States market. After its 2016 launch in Colorado and subsequent expansion to other western states, Zyn's retail presence surged. From approximately 13,500 U.S. stores in 2018, distribution expanded to around 100,000 stores by 2020.

Sales performance has been equally impressive, with can sales jumping from 83.2 million to 125.7 million between 2020 and 2021—a 40% increase. Several key factors have driven Zyn's market success:

1. Its tobacco-free formulation subjects it to fewer regulatory requirements than traditional tobacco products

2. Its discrete nature—no spitting needed, no smoke produced, minimal odor

3. Multiple nicotine strength options to accommodate different user preferences

4. Strategic marketing approaches, including "unflavored" variants such as "Smooth" and "Chill" that help navigate flavor ban regulations

Consumer Engagement and Rewards

Zyn created a rewards program to build customer loyalty. Through the Zyn Rewards Program, consumers earn points through brand interactions. The main way to earn points is by purchasing Zyn products and entering special codes into their Zyn accounts, with each code worth 15 reward points.

Members can also earn points by sharing Zyn content on social media and referring friends. The points are redeemable for branded merchandise at the Zyn Rewards Store, including bags, hoodies, bottle openers, posters, cornhole sets, aprons, range finders, brumates, and grills.

This merchandise effectively turns Zyn consumers into brand ambassadors as they use and display Zyn-branded items in their daily lives.

Summary

Zyn nicotine pouches are manufactured primarily at the Owensboro, Kentucky facility in the United States, where a $115 million expansion was completed in 2019. The product originated in Sweden in 2016, with initial production there before expanding to meet growing U.S. demand.

In 2022, Philip Morris International acquired Swedish Match, Zyn's creator, bringing the manufacturing operations under new ownership. The Kentucky facility now produces over 125 million cans annually, reflecting Zyn's 70% market share in the U.S. nicotine pouch industry.

The manufacturing process combines microcrystalline cellulose as a base material with nicotine salt to create tobacco-free pouches in varying strengths. While these products contain no tobacco, they still contain nicotine and carry health considerations that shape production and regulatory requirements.

Under Philip Morris International's ownership, Zyn's manufacturing locations and processes may continue to evolve as the product grows in availability and popularity.

Resources to Quit Smoking

• Smokefree.gov - Provides tools, tips, and support that can help you quit smoking.

• Centers for Disease Control and Prevention (CDC) - Quit Smoking - Offers resources on how to quit smoking, including tips on quitting, benefits of quitting, and quit plans.

• American Cancer Society - How to Quit Using Tobacco - Provides detailed information on why to quit, how to quit, and dealing with the emotional and physical aspects of quitting.

• Mayo Clinic - Quit Smoking - Features articles, tools, and tips on quitting smoking and overcoming nicotine dependence.

• Truth Initiative - Provides innovative tools and resources for young people, including a text-to-quit program.