Cold Process Soap Making

At a glance:
Community of Practice - Other
Type: Workshop
Duration : 1 hour and a half active work, 4-6 weeks for
the soap to cure
Min/Max participants: N/A
Room/space requirements: A kitchen with a source of
heat. If this isnt suitable you will need portable
electric/gas hobs.


Objectives
To learn how to make solid soap and understand how
soap can help develop a social enterprise




EWB-UK Training
Hand Over Pack

1. Introduction
This is one of the workshops run at the Small is festivals..
Soap making forms a suitable basis for a sustainable social enterprise abroad. Projects in
Tanzania, South Africa and Nigeria have been set up to train the local community in how to
make soap. People can create a sustainable business from this on either a small or large
scale.
2. Venue
A kitchen with a source of heat
If this isnt suitable you will need portable electric/gas hobs.
3. Accommodation
4. Food
5. Typical Itinerary
Time Activity Equipment
5 minutes Welcome
5 minutes Introduction
5 minutes Theory
40-80 minutes Practical See material list
5 minutes Wrapping Up
5 minutes Closing Sign-ups for email

6. Session Information
Preparation
Read background material
Prepare equipment, tools and materials
Prepare sign-up sheets for new members
Welcome (5 minutes)

Introduce yourself:
Your Name
Position/Job/Organisation
Your role in the workshop
Relevant experience to the workshop (University, projects, work etc.)

Explain the learning objectives of the workshop to the audience:
The purpose of this workshop is for participants to learn how to make their own bar of soap.
The method used here is the cold process method. Some heating is required but it is very
low temperature. The recipe used here is a basic soap recipe however there are many other
recipes which use different ingredients to achieve a specific type of soap
Soap making may not appear relevant to the issue of sustainability or development however
it forms a suitable basis for a sustainable social enterprise.
Also discussed in this workshop is a bit on the science behind soap; the chemical reactions
that take place to create it.
Introduction (5 Minutes)
A look into how soap is relevant in the developing world
Soap making forms a suitable basis for a sustainable social enterprise abroad. Projects in
Tanzania, South Africa and Nigeria have been set up to train the local community in how to
make soap. People can create a sustainable business from this on either a small or large
scale.
Soap making requires very little materials and equipment. The majority of the ingredients
are easy to get hold and often found in the local community. Things like packaging for soaps
offers further social enterprise opportunities
What makes soap so attractive as a social enterprise is its flexibility. On a small scale people
can make soap and sell it within their community however with funding or continued growth
a company making and selling soap can employ a significant number of people. With enough
success the soap can be begin to be exported
Theory (5 Minutes)
A little bit about the science behind soap making
The main process involved in soap making is saponification. Saponification is the name for a
chemical reaction between an acid and a base to form a salt. In the cold process method you
mix an oil or fat (Acid) with Lye (Base) to form the soap (Salt)
The base must always be composed of one hydroxide ion. Here you are using lye (Sodium
hydroxide) which contains one sodium ion and one hydroxide ion. The sodium ion doesnt
take part in the reaction, just the hydroxide ion. Other bases can be used such as potassium
hydroxide but this is normally used for liquid soap
The acid can take a variety of forms. Each acid has a unique combination of triglycerides
(Compounds with 3 fatty acids attached to a single molecule of glycerol). The amount of
base required to react with the acid will depend on the chemical structure of the acid
When the acid and base are mixed together the triglycerides release the single glycerol
molecule (Which turns into skin nourishing glycerine) which enables the fatty acids to
combine with hydroxide ions to form soap.
Essentially two reactions occur. The first is turning the glycerol into glycerine and the second
is the acid and base reacting to form the salt (soap)


w is the saponification table. It is a table demonstrating how different acids affect the
outcome of the soap. Explaining the terms:
1. SAP How many milligrams of baser is required to completely saponify 1 gram of an
acid. This is normally given in terms of how much potassium hydroxide is needed
2. Hard/Soft How hard or soft the bar of soap will be. If a bar of soap is too soft it will
dissolve too quickly and become too mushy. The desired outcome is achieved by
combining hard and soft oils
3. Cleansing This is how well the acid cleans. Any soap will clean relatively well
however some soaps will be better than others.
4. Fluffy Lather This is how fluffy the lather created by the soap is. A fluffy lather is
thick and bubbly but will wash away easily so is not desirable
5. Stable Lather A bar of soap with a stable lather has very little substance but is
harder to wash away. A balanced lather with be both fluffy and stable
6. Skin Care How beneficial the soap is to the skin. This is judged in terms of
nourshing vitamins, mildness and moisturizing abilities.
For the recipe in this guide you are using 3 different oils. These oils when combined will
produce a soap with desirable qualities.
Acid SAP Hard/Soft Cleansing Fluffy Lather Stable
Lather
Skin Care
Avocado Oil 133.7 Soft Fair Yes No Very good
Coconut Oil 191.1 Hard Very good Yes No Fair
Castor Oil 128.6 Soft Fair Yes Yes Good
Olive Oil 125.3 Soft Good No No Good
Palm Oil 142 Hard Very good No Yes Fair
Peanut Oil 137 Soft Fair No Yes Good
Soybean Oil 135.9 Soft Good No Yes Fair
Sweet
almond Oil
137.3 Soft Good No Yes Very good
Jojoba Oil 69.5 Soft Fair No Yes Good
Kukui Nut
Oil
135.5 Soft Good No Yes Good
Lard 138.7 Hard Good No Yes Fair
Tallow 140.5 Hard Good No Yes Fair

Practical (40-80 minutes)
Step by step guide on how to make soap. The reason for the varied length in time is due to
Step 10. This step can happen relatively quickly or can take a large amount of time.
Step 1
Weigh out 209 grams of lye using a digital scale.
Health & Safety: Lye is an extremely caustic chemical that will burn your skin upon
contact. Do not let this chemical touch you in any way. Wear rubber gloves at all times and
if available, wear protective eye goggles. Warn participants not to breath in or sneeze near
the lye. Always have a bottle of vinegar by your side. If you spill any lye, pour vinegar over
the mess to neutralize the chemical.
Step 2
Weigh out 567 grams of distilled water in a heat safe jug
Step 3
Add the lye to the water while stirring the solution with a suitable utensil (Wooden or
rubber spoon). Keep mixing until all the lye is dissolved in the water. The reaction will cause
the mixture to heat up so be aware of this. This step may take time so avoid rushing it and
spilling the mixture
Step 4
Once the lye is all dissolved the mixture needs to cool down to 35
o
C before it can be mixed
with the other ingredients. Set it one side but remember to keep an eye on it
Step 5
Measure out 751g of Olive Oil, 468g of Coconut Oil and 283g of Palm Oil. It is probably best
to do this in separate bowls
Step 6
Melt the 2 solid oils (Coconut and Palm) to liquid in a saucepan. Do this on a low heat as you
dont want to burn the oils
Step 7
Once the two oils have liquefied add the olive oil to the mixture.
Step 8
Both the temperature of the oil mixture and the lye/water mixture needs to be the same at
35
o
C before combining them. In most cases you will need to raise or lower the temperature
of one or both of the mixtures. To raise or lower the temperature you can put the pan in a
sink filled with hot or cold water.
Step 9
Once both mixtures are at 35
o
C the lye/water solution should be added slowly to the pot
with the oils. Using the mixing utensil you should stir in a figure of eight pattern to ensure
that the lye and oils mix properly at this point
Step 10
Keep stirring until you see trace. To test for trace, drizzle a small amount of the mixture off
the end of your utensil over the solution. If the liquid remains on top of the surface for a
brief amount of time before sinking back in then trace has occurred. At this point
saponification has taken place.
This step can take a very long time or happen rather quickly. At the earliest it will happen
after 10 minutes of stirring although it can take about an hour. You should regularly test for
trace, about every 5 minutes, to ensure you dont miss it. If you go past the point the soap
will begin to solidify in the pot and will be very difficult to pour. To make searching for trace
easier ensure your area is well lit. If your pot doesnt have a clear light shining on it you
might not be able to see trace clearly
The reason for the time being so varied is due to a number of different factors. The way in
which the solution is stirred and with which utensil you use can affect the time. The accuracy
of the weight of the ingredients as well how similar the temperatures were can also play
their player
Step 11 (Optional)
Add any essential oils, nutrients or colorants after trace. This is the step where you can
personalise your soap to make it smell and look the way you want. If any extras are added
ensure they are will mixed in evenly
Step 12
Pour the soap into your mould(s). A pyrex oven dish is appropriate. If any of the solution
sticks to the side of the pot when pouring it should be left. There is a possibility it did not
saponify fully
Step 13
Place the lid on your mould or a piece of cardboard or heavy duty freezer on top. This is to
seal it from the air. The mould should be wrapped in a few blankets or towels to help
insulate it
At this point the workshop for the day ends. The next few steps should be carried out by
the facilitator in their own time. The completed soap (Step 16) could be given back to the
participants at a later course/event.
Step 14
Let the soap solidify for at least 24 hours. It may take up to 48 hours to completely solidify.
Step 15
When the solution has solidified it should be removed from the mould. This will require a
large sharp knife. Once removed from the mould it can be cut into bars however large you
choose
Step 16
Each bar can be placed on a wire rack to cure. The curing process can take about 4-6 weeks
so best to leave it for 6 weeks to be on the safe side. After this it is ready to use. The bars
should be flipped over about once a week during the curing process. Before using them any
white powder that has formed on the surface should be removed. This is called soda ash and
can be drying for the skin

Wrapping Up (5 minutes)
Conclude the workshop
Below is the saponification table. It is a table demonstrating how different acids affect the
outcome of the soap. Explaining the terms:
1. SAP How many milligrams of baser is required to completely saponify 1 gram of an
acid. This is normally given in terms of how much potassium hydroxide is needed
2. Hard/Soft How hard or soft the bar of soap will be. If a bar of soap is too soft it will
dissolve too quickly and become too mushy. The desired outcome is achieved by
combining hard and soft oils
3. Cleansing This is how well the acid cleans. Any soap will clean relatively well
however some soaps will be better than others.
4. Fluffy Lather This is how fluffy the lather created by the soap is. A fluffy lather is
thick and bubbly but will wash away easily so is not desirable
5. Stable Lather A bar of soap with a stable lather has very little substance but is
harder to wash away. A balanced lather with be both fluffy and stable
6. Skin Care How beneficial the soap is to the skin. This is judged in terms of
nourshing vitamins, mildness and moisturizing abilities.
For the recipe in this guide you are using 3 different oils. These oils when combined will
produce a soap with desirable qualities.

Closing (5 minutes)

Final few words:
Announce next event or meeting
Announce when soap can be collected
Distribute sign up lists (If applicable)
Open the floor to questions


7. Useful Resources
Soap making recipes and tutorials:
http://www.soap-making-resource.com/index.html
A few examples of soap making as a social enterprise:
http://www.makesoap.biz/
A company that makes soap as a bi-product of biodiesel:
http://jatrophafoundation.org/jatropha_curcas.html
How to make soap from the waste material of biodiesel:
http://www.permaculture.com/node/535
JUSTaSOAP, a useful shop for buying soap supplies online:
http://www.justasoap.co.uk/catalog/index.php

8. Materials
For 5 pounds (2.267kg) of soap:
Olive oil (26.5 ounces/751g)
Coconut oil (16.5 ounces/468g)
Palm oil (10 ounces/283g)
Lye (209 grams)
Your choice of essential oils (2.7 ounces/77g - optional scent)
Distilled water (20 ounces/567g)
9. Tools
Protective gloves and goggles should be worn when dealing with the Lye.
Weighing Scales
Re-sealable bag
Heat safe jar
Stirring utensil ( e.g. Wooden Spoon)
Thermometer
Bowls (For measuring)
Saucepan (For heating oils)
Large Saucepan (For mixing everything together)
Pouring jug (optional, for easier pouring of lye mixture)
Soap Mould (With lid if preferable)
Blankets/towels
Knife (For cutting soap)
Wire rack for cooling
Sharp knife

10. Feedback
11. Costings this could be the budget spreadsheet attached as an
appendix
Item Quantity Price per
unit
Total






12. Joining Instructions as an appendix?
13. Risks to consider (to guide a risk assessment form)
Potential Risks Mitigation Strategy




14. Organiser Checklist see relevant generic checklist