Video: How to Achieve Accurate Bar Size in Soapmaking

There are three ways to cut cold process soap loaves into bars: by hand, with a manual cutter, and with an electric cutter. The disadvantage to cutting soap by hand is that it is challenging to get consistent bar size and accuracy. If you currently cut soap by hand, try weighing each bar and see how close each one is in weight. Surprisingly they can be as much as .5 oz or more different. Also, it's next to impossible to scale your soap business with cutting soap by hand. Imagine cutting thousands of bars by hand.

When we move to a manual or electric cutter, our accuracy increases and so does the professional appearance of our soap bars. I prefer a manual cutter to an electric one, the reason being is that it takes so much time to replace cutter blades from loaf cutting to bar cutting.

In the following video I'll show you how we easily cut loaves into bars. This particular batch yielded 27 loaves, which in turn produced 378 bars of soap.

How do you cut your soap? Do you have any tips to share?

Thanks for watching!
~Marla

How to Make 100 lb. Batch of Handmade Soap

Like many soapmakers, I started my business in my home kitchen, making small batches of soap. As demand for my products grew, I found myself outgrowing a stockpot, then a 5 gallon pail. Stickblenders were no longer large enough to emulsify a batch of soap.

After much research, I invested more than $10,000 in soap making equipment: water-jacketed electric tanks to melt oils, large stainless steel mixing pot on tipping stand, 350 bar molds, drill with paddle attachment to replace stick blender, electric soap cutter, more stainless steel tables and baker's racks.

In this video I'm making a 100 lb. batch which will yield approximately 400 bars of soap. I'm mixing my oils and lye water together and getting ready to add essential oils and herbs. Let me show you how I combine 10 lbs. of lye, 73 lbs. of oils/butters and 56 oz. of essential oil!

As a business, we need to be mindful of operating efficiently. What areas of your production would you like to improve?