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Without
fail, the number one question we're asked is, "How do you make soap?"
Actually, it's a fairly simple--yet magical--process that is not unlike
cooking fine food from scratch. The only difference is that we don't actually
cook the soap (and we don't eat it!). Instead, we make soap in the time-honored
"cold kettle" method, a process in which the soap is created at low temperatures
ensuring the natural nutrients and healing benefits of the herbs and essential
oils are retained--and made readily available to your skin.
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First, we gather the tools
of the trade: Stainless steel pots and spoons, digital scale, wooden spoons,
plastic pitchers and of course, safety equipment such as eye goggles, rubber
gloves and protective clothing to handle sodium hydroxide (lye), which is
what turns ordinary vegetable oils into our luscious, creamy soaps! |
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Once all the components are assembled, we measure each ingredient to within
1/10th of an ounce. This precision is important for consistency, mildness
and stability. It is what keeps our soaps so gentle and nourishing, instead
of nearly tearing your hide off like Grandma's laundry soap used to do
(Sorry, Grandma)!
The first ingredient is lye (sodium hydroxide), which we will then mix
with pre-measured, purified spring water. The solution will heat up to
nearly 200 degrees in a matter of minutes due to the exothermic
reaction--the same type of reaction which causes plaster to heat
up when mixed with water.
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While the lye and water are cooling, we move
on to measure all the solid fats--or butters--which will make up the base
of our soap. Here, we're measuring organic coconut oil, which is responsible
for the abundant, lovely lather that is a signature of WoodSprite Organic
Soap. This is when we add organic shea, organic cocoa, mango and organic
palm butters, too. |
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Once all the solid fats are measured, they are heated to a low temperature
of 100 degrees farenheit. This is the only external heat applied to a cold-kettle
soap; just enough to melt the solid butters together with the primary base
of Organic Extra Virgin Olive Oil, which we feel makes a superior moisturizing
soap. We'll also add other exotic oils like Organic Sweet Almond, Avocado,
Rice Bran, Sesame or Kukui, which provide extra nourishment and moisturizing
properties to the skin.
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While the lye cools and the fats melt, we measure
out the Certified Organic herbs and botanicals, then the pure Essential
Oils which give our soaps their intoxicating, irresistable natural scents.
This batch is Patchouli, so we'll be using Pure East Indian Dark Patchouli
Essential Oil and Certified Organic Black Walnut Hulls for a rich, chocolatey
color. |
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Now that all the oils are melted together and the lye solution
has cooled to approximately 100 degrees farenheit, we carefully stir the
lye into the oils.
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Using a spoon and hand-blender,
we mix rapidly to ensure thorough blending of each lye molecule with each
fat molecule. These molecules will all break apart and then reassemble into
a totally new one, comprised of two fatty acids and a glyceride (glycerin),
the magical secret which makes handmade soaps so soothing and moisturizing.
This is creative alchemy at its finest! Gold for the skin. |
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It only takes about 15 to 30 minutes of mixing for the lye-water
and oils to thicken together, resembling a thin pudding. This thickening
stage is called "trace", and it means that most of the molecules are now
linked up. It's also the signal that we need to add the herbs and essential
oils because the thickening will speed up fast!
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After all the organic botanicals and essential
oils are added, the soap is very much the texture of pudding. It's time
to pour the soap mixture into the mould--a lined wooden box that we can
disassemble in order to cut the soap. |
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Once all the soap is poured into the lined mould, we'll cover
and insulate it with blankets, which will enable the saponification (or
transformation into soap) to be completed over the next 48 hours.
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After 48 hours, the mixture will be a solid,
35-lb. block of pure organic soap. Once it is unmoulded and the liner is
removed, we'll cut it by hand into logs, then individual bars. |
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The cut bars will be placed on a curing rack and allowed to age over the
next month--much like fine wine or cheese. This curing process allows
the excess water to evaporate, making the organic soaps milder, harder
and longer lasting.
After a month, the fresh organic soaps are carefully labeled by hand and
placed into special wooden drawers, ready to be sold and shipped to you.
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