How Is Nicotine Made?

Nicotine is produced through 2 main methods:

1. Tobacco Leaf Extraction – Cured tobacco leaves are treated with solvents to extract nicotine, followed by purification to isolate the compound. 
   
   
2. Synthetic Production – Nicotine is chemically synthesized in a laboratory using organic compounds. The process involves multi-step synthesis and purification to produce ≥99.9% pure (S)-nicotine, identical to the natural molecule but free from tobacco-derived material and DNA. 

These methods result in nicotine used in modern products like pouches, gums, and lozenges. 

Nicotine, found naturally in a variety of plants, has been around for centuries — but it’s most known for its presence in tobacco. Traditionally associated with products like cigarettes and cigars, nicotine today goes far beyond smoking. It’s found in smoke-free formats like nicotine pouches, lozenges, and other modern alternatives.

As these products evolve, so do the methods used to make the nicotine inside them. In this article, we’ll break down how nicotine is made, the different types of nicotine used today — including synthetic nicotine and tobacco leaf-free nicotine — and why the source matters for both manufacturers and consumers.  

Nicotine is a naturally occurring compound found in certain plants — primarily those in the nightshade family (Solanaceae). At its core, nicotine is an alkaloid — a nitrogen-containing compound that plants produce, often as a defense mechanism against insects.

While tobacco (Nicotiana tabacum) is the most well-known and commercially viable source, trace amounts of nicotine can also be found in plants like tomatoes, eggplants, and potatoes—however, these quantities are far too low for commercial extraction:  

• Eggplant: ~100 nanograms/gram 
• Tomato: ~40 nanograms/gram 
• Potato: ~7.1 nanograms/gram  
• In the case of tobacco, nicotine concentrations can range from 0.6% to over 3% in the leaf, which is approximately 100,000 to 300,000 times more than the above listed vegetables, making it highly extractable for commercial use.  

Historically, the most common method of producing nicotine is by extracting it from cured tobacco leaves. Here's how it works:  

• Harvesting: Mature tobacco plants are harvested and dried.  
• Extraction: The dried leaves are treated with solvents (such as ethanol or water) or processed using supercritical CO₂ to extract nicotine.  
• Purification: The raw extract is then refined to isolate pure nicotine. Advanced filtration methods remove impurities, including potentially harmful byproducts.  
  
  

This process results in tobacco leaf-derived nicotine — a highly concentrated liquid used in many nicotine-containing products. But because this nicotine comes from the tobacco leaf, it can contain trace amounts of tobacco-specific nitrosamines (TSNAs) — chemical compounds that develop during the curing and aging process. 

TSNAs like NNK and NNN are closely monitored by health authorities due to their potential health risks. This is one reason why some manufacturers are exploring alternative methods for producing nicotine. Reducing or eliminating harmful TSNAs can lead to a better product — and for many consumers, that matters.  

We’ll cover what TSNAs are, why they’re important, and how newer forms of nicotine production address them later in the article. 

As nicotine products continually evolve, so do the methods of producing different forms of nicotine. One modern approach is tobacco leaf-free nicotine. Unlike traditional methods, this type of nicotine is still derived from the tobacco plant, but not from the leaf.

Instead, it’s extracted from other parts of the plant, like the roots or stems, which also contain nicotine-producing cells. The process follows the same basic principles of extraction and purification but uses non-leaf biomass as the source. The result is a highly purified nicotine that contains no actual tobacco leaf material, although it may still contain trace tobacco DNA, which is why it's legally still considered tobacco-derived.  

Unlike tobacco-derived forms, synthetic nicotine is created entirely in a laboratory setting — with no plant material involved.

Synthetic nicotine is produced using chemical building blocks and these compounds go through a multi-step chemical synthesis that results in nicotine molecules identical to those found in nature.

Key steps include:  

• Chemical Synthesis: Scientists assemble the nicotine molecule from its base elements using precision organic chemistry. 
• Isomer Control: The goal is typically to isolate the (S)-nicotine isomer. Some synthetic methods produce a 50/50 mix of (S)- and (R)-nicotine, but newer techniques focus on optical purity. 
• Purification: After synthesis, the nicotine undergoes multiple purification stages, often resulting in ≥99.9% purity. 
• Quality Control: Rigorous lab testing ensures there is no tobacco DNA, no TSNAs, and no unwanted residues. Because synthetic nicotine does not originate from the tobacco plant, it is often referred to as tobacco-free nicotine in a more literal sense.  

Nicotine salts — or nic salts — are another modified form of nicotine. Unlike freebase nicotine (the standard form used in most products), nic salts are made by combining nicotine with an acid (commonly benzoic or citric acid). This creates a more stable compound with less throat harshness.  

Nicotine salts are produced by:  

• Starting with freebase nicotine (from either tobacco or synthetic sources)  
• Reacting with an acid to form a salt  
• Formulating the result into products like e-liquids or nicotine pouches 

That depends on the source of the original nicotine. Nicotine salts can be: Tobacco-derived (leaf or leaf-free) or Synthetic. The acid doesn't change the source — it simply modifies the form.  

Tobacco-Specific Nitrosamines (TSNAs) are a group of potent carcinogens uniquely formed during the curing, aging, and processing of tobacco. They are not present in fresh tobacco leaves but develop over time through chemical reactions involving tobacco alkaloids (like nicotine) and nitrosating agents.

The primary TSNAs of concern include: NNK (4-(methylnitrosamino)-1-(3-pyridyl)-1-butanone) NNN (N′-nitrosonornicotine) NAT (N′-nitrosoanatabine) NAB (N′-nitrosoanabasine).

These compounds are predominantly found in tobacco products and their smoke, contributing significantly to the harmful effects associated with tobacco use.  

TSNAs are recognized for their carcinogenic properties. NNK and NNN have been classified as Group 1 carcinogens by the International Agency for Research on Cancer (IARC), indicating sufficient evidence of carcinogenicity in humans. NNK is strongly associated with lung cancer, while NNN has been linked to cancers of the oral cavity, esophagus, and respiratory tract.  

Regulatory Oversight The U.S. Food and Drug Administration (FDA) includes TSNAs like NNK and NNN on its list of Harmful and Potentially Harmful Constituents (HPHCs) in tobacco products. This designation underscores the importance of monitoring and regulating these compounds to protect public health.  

At Northerner, we’re focused on providing modern, tobacco-free alternatives — which is why none of the products we carry contain tobacco leaf. Instead, our nicotine pouch assortment is made with:  

• Tobacco leaf-free nicotine: Derived from the tobacco plant, but only from non-leaf parts like stems or roots, then purified to remove unwanted compounds.  
• Synthetic nicotine: Fully lab-made, with no tobacco plant used at any stage.  
  
  

Our product pages clearly list the nicotine type where available, helping you make informed decisions. Whether you're choosing a pouch with a familiar brand or trying something new, you'll know exactly what you’re getting.