Disposable Vapes vs. Refillable Mods in 2025: September Market Breakdown

By 2025, the vaping industry has evolved well beyond the early “cigalike/first-generation e-cig” era. Among the many axes of change, one major tension remains front and center: disposable (single-use or limited-use) devices vs refillable/mod/pod systems (devices with reusable components). These two camps compete not just on features and user experience, but on regulatory risk, sustainability, margins, and brand loyalty.

Below is a snapshot of where things stand in September 2025 — what’s growing, what’s shrinking or under threat, and where both sides will likely move next.

Disposable Dominance — But Under Pressure

• Disposables continue to capture enormous volume in many regions. Many in the retail/wholesale side identify them as among the highest-turnover and highest margin lines.
• According to one industry summary, disposables are “dominating” the vaping market in 2025 thanks to convenience, broad flavor offerings, and impulse purchases.  
• A trend report notes that disposable vapes are still “the go-to” product line in 2025, while pod systems evolve incrementally.  
• Another source shows the global e-cigarette & vape market is expected to grow from ~ US$27.75 billion in 2024 to ~ US$67.11 billion by 2029, so there’s a rising tide.  

However, because disposables are inherently single-use (or limited-use), they face increasing scrutiny over waste, environmental impact, and regulatory crackdown (especially in jurisdictions aiming to reduce e-waste). Some markets are already beginning to ban or restrict outright non-rechargeable or non-refillable devices (e.g. the UK’s move to ban single-use e-cigarettes). 

Refillable/Mod/Pod Systems: Slower Growth but Strategic in the Long Run

• Refillable systems are generally seen as more sustainable (less waste per use) and may be safer in regulatory climates that target disposables first.
• One projection pegs the refillable vape market growing at a ~4.6% CAGR from 2025 onward (2025–2032).  
• The pod/mod space is evolving more by convergence: modern pod systems are borrowing features from bigger mods (e.g. more power control, adjustable airflow), shrinking the performance gap.  
• Among enthusiasts and heavier vapers, performance, flexibility, and total cost of ownership are pushing more users toward refillables/mods.  

So, in sum: disposables still lead in volume and “top of funnel” capture, but refillables remain a strategic anchor for serious users and as a hedge against regulatory risk

What’s Hot Among Disposables

1. Mega puff counts
   Devices now often promise tens of thousands of puffs per unit — 30K, 50K, even 60K+ — making them a better “value per unit” proposition.  
2. Rechargeable disposables
   The standard is shifting: users expect USB-C charging (so the battery can last the life of the device) and battery metering.  
3. Flavor complexity and niche blends
   Rather than just simple fruit/menthol, brands are pushing layered, hybrid, or dessert-style blends.  
4. 0% nicotine-free options
   To appeal to health-leaning or social users, nicotine-free disposables are gaining traction.  
5. Regulation-driven “reusable-lookalikes”
   In markets where single-use bans are coming (e.g. UK), manufacturers are releasing disposables that outwardly resemble reusable devices (charging ports, better casings) to skirt restrictions.  

What’s Gaining (or Resurgent) Among Refillable / Mod Systems

1. Hybrid/pod-mod convergence
   Devices that combine the simplicity of pods with mod-level power and control are becoming mainstream.  
2. Better chipsets/smarter features
   More advanced electronics: temperature control, safety features, real-time readings. 
3. Eco & sustainability branding
   Green credentials are increasingly important. Many brands tout recyclable parts, take-back programs, or modular designs to extend life.  
4. User lock-in via ecosystem
   The mod/refillable world leans into improved user retention by offering multiple compatible tank/coils, firmware updates, etc.
5. Regulatory environment favoring reusables
   In jurisdictions cracking down on disposables, refillables are safer long-term bets.

Regulatory & Environmental Wild Cards

• Disposable bans & restrictions: Some countries and states are outright banning or preparing to ban nonrefillable, non-rechargeable vapes. The UK, for example, banned the sale of single-use e-cigarettes starting June 2025.  
• Loopholes & product redesigns: Manufacturers are responding by releasing devices that tread the line—“reusables in disguise” or devices that cannot really be maintained but meet formal criteria.  
• E-waste & battery disposal pressures: Disposables contribute substantially to electronic waste. Critics highlight the fire risk of lithium batteries in garbage streams and the resource waste.  
• Youth use/flavor bans: Some jurisdictions are limiting use of flavored e-liquids (except perhaps tobacco/menthol) to reduce youth uptake. That squeezes the advantage disposables often get from bold flavor lines.
• Import/supply chain disruptions: Tariffs, import restrictions, or trade policy may impact cost structures, particularly for devices built overseas and shipped globally.

All this means that for manufacturers and retailers, a disposable-only strategy is increasingly risky. Hybrid and refillable lines are becoming essential hedges.

Strategic Implications & Recommendations (for Businesses/Retailers)

1. Don’t bet exclusively on disposables
   Even if they drive volume now, regulatory and environmental pressures could clamp down on them. Maintain or expand refillable/mod lines as insurance.
2. Differentiate your disposables
   When stocking disposables, lean toward units with:
   
• Rechargeable batteries
• High puff counts with credible spec
• Unique flavor profiles
• Clear compliance/lab test documentation
  
3. Build ecosystem & loyalty via refillables
   Offer bundled deals: mod + tank + premium e-liquid. Encourage users to stay in your “brand universe” via coil/pod compatibility, loyalty discounts, etc.
4. Promote sustainability features
   Emphasize take-back/recycling programs, eco packaging, detoxed waste channels.
   In markets with environmental regulation, being seen as green can help mitigate backlash.
5. Monitor local regulatory shifts closely
   Regions may ban or restrict disposables — stay alert for early signals. Be ready to pivot or phase out noncompliant SKUs quickly.
6. Hybrid lines as a bridge product
   Products that “feel like disposables but are refillable” may serve as transitional devices for users who aren’t ready to fully commit to a mod. They also may survive in stricter regulatory climates.

By September 2025, the market for disposables vs refillables is more nuanced than ever. Disposables still dominate in sheer volume and user convenience, but their advantages are under stress from regulation, waste concerns, and product saturation. Meanwhile, refillables/mods are carving out the high-value, loyal-user niche and potentially more regulatory-safe ground.

For anyone in the space — from brand to retailer to investor — the winning posture is likely hybrid: keep disposable offerings for volume and impulse sales, but build out a robust refillable/mod arm for sustainability, margin stability, and long-term resilience.