Making our Soaps...

mixing the oils in the kettle

We've been making a lot of soap lately. It is, after all, our business. And while it keeps us indoors on beautiful sunny days, it is still a labor of love.

We have been making soap since 1979, when we began as a way to provide natural & nontoxic soap for our own special needs. Sensitive to synthetic fragrances and colors, we could not find commercial soap locally that worked for us. And since that time we have never tired of creating the best soap we possibly can.

Saponification

Soap is the result of a chemical reaction called Saponification. Briefly, Saponification is the chemical reaction between fatty acids (oils & fats) & caustic ("lye", caustic soda, sodium hydroxide, etc.) that results in 98% soap and 2% glycerin. Different oils/fats and different caustic solutions can be used for different types of soap. Potassium Hydroxide, for instance, is used for liquid or soft soaps.

We start by mixing organic oils of olive, palm, and coconut together. We choose these oils for their individual benefits. Olive oil is the best for the skin. Palm creates a harder, longer lasting bar. Coconut oil is the source of rich, copious lather, without it bubbles are small and thin. These oils are heated and then we add the sodium hydroxide that starts the chemical reaction. This process requires a lot of stirring. At the point when the mixture has thickened the proper amount we add the various botanical elements that give the individual varieties their characteristics.

Dennis cutting the Orange Spice soap

Our soaps are made in rectangular columns. Once the liquid soap is ready, we pump it into these molds, cover it with an insulating layer and let it sit up to 48 hours before it is ready to cut into bars. Our soap cutter is a machine of our own devising, custom made by us for our soaps. Once cut we place the soaps on trays, then on ventilated shelves, where it cures for at least 3 weeks before we wrap it to sell.
We wrap the soap by hand. Each bar is wrapped in ecologically sustainable Thai mulberry paper, then labeled with a recycled paper band. You've probably noticed we color code our soaps: each variety has its own specific color paper.

Wrapping Lemon Shea Butter soap

Our soap shop has evolved a lot over the years. Starting by making soap in our kitchen, our original shop was built from trees we fell and milled ourselves (5 big buggy Douglas fir that were dying).
We outgrew that in a few years and expanded it into the shop we have today.




Here is a quicky version of the photo tour we have on our website:

Our kettles, lye station & manufacturing area

Where we wrap & label the soaps, etc.

The curing room with our renewable energy power wall

With over 30 years of soap making experience, it is our pleasure to provide you with the finest natural organic soaps. It makes us even happier to be able to do it in the most environmentally conscious way we know how. To learn more about our business and philosophy, please see 'About Us'.

Manual Production

Living off the grid, as we do, gives you a fine sense of power use. When you can use people power effectively you tend to forgo modern machinery with motors.
Once in a while you can be lucky enough to find a perfect piece of equipment from the past that was developed to do the job you need. That is the case with our paper cutter.

This is our guillotine. 100 years old when we bought it, an antique print shop manual paper cutter. That's one big chunk of cast iron!

You probably already know we use environmentally friendly Thai Unryu paper made from Mulberry trees to wrap our soaps.
These fine handcrafted art papers come in large sheets that need to be cut into smaller size to wrap the individual bars of soap.

Cutting the sheets individually is not an option, a print shop style paper cutter, or guillotine, cuts a large stack of paper all at one time. Most modern guillotines are powered by hydraulic motors. This is one of the original manual ones.
You can still buy manual bulk paper cutters, but they are not as beautiful a piece of machinery as this!

You put a stack of paper on the table after adjusting a stop to the proper length, using the wheel you see in front, then turn the wheel on top to clamp it down.
The blade (reflecting the paper) comes down by pulling/pushing a long handle activating a lever. Then it is held back by a counterweight. Primitive machinery, but very effective. 

After cutting into strips the proper width, you readjust the stop and cut into rectangles.
Below you can see the stop on the back of the cutter.

Here you can see the size of the original sheets of Unryu mulberry paper, a cut strip, and the finished size.



On the right is the cut paper for our bath bars, with smaller paper for mini soaps in front.

Below is paper, and soap waiting to be wrapped.
We wrap all the soaps by hand as well.
 Just a peek into how we do things here at Simmons Natural Bodycare.