FACT FILES ON HANDMADE PURE, ORGANIC SOAP

Quite a few customers at the markets on the weekend, quizzed me over soap making methods and safety issues...highly unusual. The odd person occasionally asks some questions- a few...tweaked my curiosity.

Then my memory likes to wander around and search for relevant fragments…triggered by words/associations. So now it’s replaying that infamous torture scene from the movie “Marathon Man”, where Dr Szell (Sir Lawrence Olivier) asks Babe Levy (Dustin Hoffman), “Is it safe?”…before wielding the dental probe into Levy’s decaying tooth. How could anyone attend a dental appointment thereafter, without apprehension? My memory grabs on to trivia and files it away.

Apparently, various soap making workshops have been run recently in Brisbane, & the take home message from that exercise in my opinion is that not enough information has been passed on to attendees over the importance of safety practices in handling caustic soda...with children attending these workshops also. I've refused to run soap making workshops because of safety issues...my business insurance would be promptly terminated!

As I’ve explained before, a caustic soda (sodium hydroxide/NaOH)/water solution or ‘lye’ is required to make soap. NaOH is a highly corrosive, caustic and reactive chemical, and it should always be handled with appropriate safety precautions in place.

Caustic soda is produced from an electrolysed sodium chloride brine solution. This process works in much the same way that chlorine is produced for salt water swimming pools- the salt water being passed over the charged plates of the chlorinator cell which breaks down the salt into its natural components…one of which is chlorine.

Caustic soda is a strong alkali and highly corrosive. When it is used commercially, stringent safety precautions are required:
-       chemical resistant clothing/apron, shoes, protective gloves and safety glasses/face shield must be worn
-       the area must be fitted with a fume exhaust hood, safety shower and eyewash fountain
-       NaOH must be stored in a dry place- away from metals, and locked away from child access.

Now there are some clues that should be observed with good reason.

NaOH is:
-       both colourless and odourless
-       slippery when wet
-       exothermic, generating extreme heat when exposed to moisture…heat sufficient to cause skin burns on contact
-       capable of melting some plastics from the generated heat when mixed with water
-       unstable when combined with anything other than lukewarm water…if the water is either too hot or cold, a volcanic reaction can occur
-       corrosive as a generated vapour/mist, and a respiratory irritant…severely damaging nose, throat and lung tissues
-       highly corrosive and capable of dissolving animal proteins…causing severe skin burns on contact
-       reactant with several metals…causing the highly explosive and flammable hydrogen gas to form- only stainless steel can be contacted safely
-       capable of producing deadly carbon monoxide gas, when in contact with any sugar.

That’s quite an extensive list of cautionary notes to be mindful of whilst handling NaOH in soap making. Accidents happen…without question. I have visions of spilling the lye on the floor- then falling over on the slippery surface and having my clothes drenched in the burning solution…and unable to get up! Only once have I had an accident- a tiny NaOH grain went unnoticed on a fingertip while I worked. It burnt a tiny deep hole through all layers of skin quickly.

Never become complacent over handling this chemical. I am acutely aware of safety issues always- even after making soap daily for several years. I wear protective items. I mix the water and caustic soda outside in fresh air. I use thermometers. I keep a bottle and bowl of vinegar on the bench- ready to neutralise any splashes/spills. I have the security of a swimming pool a step away from the workroom to jump into immediately. I take no obvious risks ever- one splash of the solution in my eye could cost me my sight.

I have taken issue over soap making kits being sold and promoted as an activity to be done by children. I find this prospect outrageous. Even with adult supervision, accidents happen in a split second. Children do not develop acceptable levels of thought processing and physical co-ordination skills until after the age of 10 years.

Beyond the potential recipe for disaster in a child handling NaOH, a child is curious and impatient. Once the soap is mixed and poured, it is left to firm up for 24 hours. The process of saponification continues during this period. The soap mixture goes through various stages as the molecular changes occur. The mixture generates its own heat, and gradually goes in to a clear gel state- starting at the centre and gradually expanding outwards to the edges. During this period, the mixture is still highly corrosive- it could in fact be used as a paint stripper. Do you really want a child impatiently poking their finger in to the mixture to gauge how firm it is?

Anyone using caustic soda to make cold process soap for public sale is required to be registered with NICNAS- National Industrial Chemicals Notification Scheme, Australian Government Dept. of Health and Ageing. Anyone not registered is liable to hefty fines- $33K for an individual/$165K for a company. If a soap maker makes a mistake in their calculations or measurements of caustic soda, severe burns could result.

Soap makers are also required to carry product insurance to protect the buyer’s health interests. Unfortunately, soap is now viewed as a high risk insurance item- largely because of claims brought about through many body-washes, which have a high margin for error in mixing. Product insurance for soap has escalated- with few insurers prepared to cover soap/related products- with insurance costing me 40% of every sale. That doesn’t leave much scope for profitability in the equation.

So my take home message to those thinking about making their own soap…please take note of the safety issues surrounding the use of caustic soda. Never treat it casually…ever!

Some safety tips in soap making to always observe:
-       wear protective chemical resistant gear
-       work in a well ventilated space
-       measure ingredients accurately
-       only use hardened glass and stainless steel utensils
-       have ready access to a water supply for emergency use
-       have ready access to vinegar…the acid will neutralise the alkali caustic soda
-       use thermometers in both the lye solution and oils before mixing at same lowered temperature
-       add caustic soda SLOWLY to lukewarm water- if added too quickly, corrosive vapour will form…which should not be breathed
-       never add water to caustic soda…a volcanic eruption will occur, causing dangerous splashes- only add NaOH to water
-       wash hands thoroughly after soap making
-       wash equipment used in isolation of anything else
-       reserve any equipment used solely for soap making
-       keep caustic soda and poured soap mixture out of the reach of children.

As I’ve explained before, caustic soda- although used to make soap- does not exist in the final soap product. It is a part of a manufacturing process, and it is rendered inert within 24 hours of combining the ingredients…resulting in a solid soap salt and glycerine as a by-product instead.

Back to “Marathon Man” and its relevance to safety in soap making. Levy answers, “No, it’s not safe- it’s very dangerous- be careful.” The memory dots are connected!

FACT FILES ON HANDMADE PURE, ORGANIC SOAP

How is soap made? Often when I’m stirring a batch of soap, I hear the words silently running through my head…”Double, double toil and trouble; Fire burn, and caldron bubble.” (from Macbeth, William Shakespeare)…some words stick with you for life!

So how do you turn an oil into a solid to create soap? There’s a bit of simple chemistry that applies to the process. Basically, a fatty acid/oil is combined with an alkali/caustic soda (NaOH) to form a solid/fatty acid salt…soap. The reaction that occurs: fat/oil + 3NaOH/sodium hydroxide = glycerine +3soap.

A fatty acid has a unique combination of triglycerides…compounds made of 3 fatty acids attached to a single molecule of glycerol. Glycerol is the basis of all fats, made up of a three carbon chain…connecting the fatty acids together. When mixed with the alkali solution with 1 hydroxide ion (the sodium ion does not take part in the reaction at all), the triglycerides within the fatty acid/oil release the single glycerol molecule…which turns into glycerine. The fatty acids combine with the hydroxide ions to form a solid soap salt.

This process is called ‘saponification’- the oil used as an ingredient becomes termed a ‘saponified oil’ for identification, or is identified as a salt- like sodium cocoate (saponified coconut oil). There is no other way to turn an oil into a solid salt. The caustic soda solution- sometimes termed ‘lye’- is part of the chemical process but, through the molecular reconfigurations in the equation, becomes inert and transforms the glycerol into the beneficial element of glycerine.

Glycerine is therefore created as a by-product of the soap-making process…making the use of caustic soda in the process a bit of a no-brainer for any concern, as it does not exist in the resultant soap. Glycerine is an incredibly moisturising substance- attracting moisture from its surroundings…a 'humectant'. It’s the most valued ingredient used in the skin care industry, and it is usually filtered off in commercial soap manufacturing to be used in moisturisers.

At ilo ORGANICS, we hand-make our soaps using the cold process method of soap manufacture. This method yields a high percentage of natural glycerine, and the glycerine quality in our soaps cannot be surpassed, as it is derived from processing pure organic plant oils. All handmade, cold process soaps can in fact be termed ‘glycerine soaps’ because of the high glycerine content produced as a by-product. 

After the mixture has thickened through careful blending, it is poured into moulds and left for a day to continue the saponification process and firm up. The formed soaps are then left to ‘cure’- evaporate the water content from the lye used, and further harden- for a period of weeks. This period is determined by the soap cake size and the oils used- varying from 4-8 weeks in our soap types produced.

At ilo ORGANICS, we ‘superfat’ our soaps. This means that in our soap recipe calculations, we make an allowance so that not all of the oils are converted in the processing. This leaves a percentage of the oils in their natural form to further moisturise the skin. These suspended oils can sometimes rise to the surface- causing small pockets of darker discolouration. The clear sticky coating that also rises to the surface of the soap is the glycerine content.

So if you were thinking that soap was the harsh product that commercial manufacturers now marketing body-washes in their economic drive would have you believe, think again. Handmade, cold process soaps are true soaps made with time-honoured traditions and natural ingredients- unsurpassed for the gentle, moisturising cleansing care that they offer the skin.

At ilo ORGANICS, our soaps also offer the added benefit of being made with pure organic plant oils, and are completely chemical, colouring and fragrance free. Indulge your body and nurture your skin naturally…you’ll wonder how you ever lived without our soaps- moisturising skin care in one simple step! Back to the stirring...

FACT FILES ON HANDMADE, PURE ORGANIC SOAP

ilo ORGANICS soaps are handcrafted using the cold process method of soap manufacture. This method ensures that the natural nutrient qualities of the selected organic plant oils used remain intact- as the ingredients are mixed by hand without the use of heat.

We have provided a brief description of the various methods used to make soap for your scrutiny. We believe that informed people make informed decisions.

COLD PROCESS METHOD- used by ilo ORGANICS

This method involves mixing a fatty acid (the oil) with an alkali (sodium hydroxide) to form a solid. This process is called saponification. The resultant soap is a fatty acid salt.

During the first 24 hours after combining the ingredients and pouring it into moulds, the molecules reconfigure- causing the mixture to generate natural heat, and progress through a transparent gel stage before becoming an opaque solid. At this point, the sodium hydroxide has been rendered completely inert- creating natural glycerine as a by-product in its place. It is for this reason that sodium hydroxide is not required to be listed as an ingredient, as it has a technical effect in the production process only, and is converted into glycerine as an ingredient.

A simple explanation of this molecular reaction is: fat (the oil) + 3NaOH (sodium hydroxide) = glycerine + 3soap.

It is the naturally achieved glycerine content that makes handcrafted soap smooth and soft in texture, and even more moisturising than from the selected plant oil content. Glycerine is a humectant- attracting moisture to the skin. Technically, all handcrafted cold process soaps can be termed ‘glycerine soaps’. There is no such thing as 100% glycerine soap. On checking commercial soap labels, the glycerine will be listed in the descending order of ingredients as an additive- along with a lengthy list of petrochemical based ingredients. A transparent soap is a heavily processed soap.

It is the natural glycerine content of cold process soap attracting surrounding environmental moisture that can turn the soap to glug. It is important to keep the soap well drained and aired between uses. For this reason, ilo ORGANICS provides a small plastic drainer for use with our soaps.

ilo ORGANICS cut the solidified soap by hand, and allow the soap to harden through evaporation for up to 8 weeks, before packaging it. ilo ORGANICS handcrafted soaps achieve approximately 12% natural glycerine content- to lavish the skin with its supremely moisturising quality. The glycerine is identified as the clear, sticky component of the moistened soap.

Soaps made by the cold process method achieve an opaque smooth, even and creamy texture- that is relatively soft in comparison to commercially produced soaps. Handcrafted soaps made from pure plant oils using the cold process method don’t require preservatives. However, ilo ORGANICS recommends that the soaps be used within 12 months of purchase.

By using this manufacturing method, the soap-maker is required to be registered with NICNAS- the Government Department that soap-making is regulated by in Australia. If the soap-maker is not registered, they are in breach of NICNAS and ACCC requirements for the manufacturing and sale of soap.

HOT PROCESS METHOD

This method uses the same combination of a fatty acid with an alkali- as does the cold process method, but the mixture is then heated for several hours to remove most of the moisture content. The resultant mixture is a thick, translucent globular gel that is then forced into the moulds rather than poured. The heating of the soap mixture allows the soap to be used immediately after solidifying- reducing the manufacturing period considerably for the soap-maker. However, the applied heat destroys the beneficial qualities of the oils by destroying the natural oil acids.

Hot Processed soaps can be identified by their opaque and slightly globular texture.

By using this manufacturing method, the soap-maker is required to be registered with NICNAS in Australia.

MELT & POUR METHOD

The melt & pour method uses either soap pellets or soap blocks that are purchased from a commercial soap manufacturer. They are therefore generally based on a highly processed, petrochemical formed soap. The purchased soap form is then heated and melted, and various ingredients (natural herbs, goat milk powders, colour, fragrance, essential oils etc) are added to the soap mixture.

Because of this ‘handling’ of the mixture, the resultant soap is technically allowed to be termed ‘handmade’, but it is no better in quality than the basic commercially produced soap purchased.

Melt & Pour soaps can be readily identified by their usually decorative appearance- either being highly coloured, fragranced, and sometimes transparent or having gimmicky forms. This method also allows the soap-maker to not be registered with NICNAS- the Government Department that soap-making is regulated by in Australia- as they are technically not the manufacturer of the soap product.

COMMERCIALLY PRODUCED SOAP

Most commercially produced soaps are technically synthetic detergent bars. They are generally manufactured from synthesized petrochemicals- with numerous buffers and preservatives added to achieve various qualities of hardness, lather etc. More chemicals are added to hasten the processing time. Look at the ingredients listed on the packaging- if you can’t pronounce it, we doubt that it is desirable to be used on the skin. Ingredients are required to be listed in descending order by percentage of content. Natural additives usually appear low on the listing- indicating minimal content, and will therefore have very little impact in the formulation.

We have done a comprehensive analysis of the ingredients of most commercial soaps- clearly identifying what all the ingredients represent or their purpose. This analysis is available to peruse to anyone visiting us at Village Life Markets- prepare to be alarmed. The petrochemical cocktail contained in one popularly promoted brand as being a moisturising “beauty cream bar” is incredibly alarming- containing 26 ingredients. This soap currently achieves 22% of commercial soap sales around the world.

Again, ilo ORGANICS believes that informed people make informed decisions. Ilo ORGANICS handcrafted soaps contain 3 or more natural organic ingredients only, to gently cleanse and nurtue the skin. There are no chemicals, colourings or fragrances added.

COMMERCIALLY PRODUCED BODY WASHES & LIQUID SOAP

Most commercially produced body washes are made from petrochemicals, similarly as to commercial soap. They could be more aptly termed ‘body detergents’.

Due to successful marketing campaigns, they have achieved escalating sales in recent years- now holding 80% of market sales. Many companies have now ceased production of soap. Naming rights to some historical brands have been sold to companies in India and Asia. Check the labels for country of manufacture- it probably won’t be what you had assumed historically any more.

Body washes are cheaper for manufacturers to produce, and their successful marketing has misguidedly lead the consumer to believe that body washes are a superior and healthier product. Because of their fluid nature, more preservatives are required to sustain the product. They present a frightening chemical cocktail presented in yet another plastic container. The application of heat is required to manufacture liquid soap. This destroys any of the beneficial qualities in the ingredients.

ilo ORGANICS suggests that you carefully read the ingredients list of body washes. One popular brand promotes that it is “soap free- pH balanced- fragrance free- colour free- paraben free”, yet contains 16 ingredients- most of which are petrochemicals. It also uses a suspected mutagenic neurotoxin as one of its preservatives. This chemical is 100% absorbed through the skin, and banned from use in all other cosmetic products. Its use is allowed in body washes because of minimal skin contact time- but do you really want to risk it? 

Again, if you can’t pronounce it, do you really want to use it on your skin?