Soap Bar Manufacturing
At Natural Resources Australia we know what makes a great soap bar. We have been manufacturing soap bars since 1995 and we are proud to be the contract manufacturer of choice for many International and local Australian Brands that want to include a superior soap bar to their range. At Natural Resources we bring together the latest soap bar manufacturing technology and manufacturing practices along with our experienced team to help turn a brands vision into a beautiful high quality finished product.
With over 20years experience we have led the industry in innovation, sustainability and natural soap bar development. All of our customers have their own unique requirements and formulation. We are flexible to work with your needs and concerns to deliver you the right product for your brand.
How is soap made?
Four Steps of Soap Bar Manufacturing:
- Refining, homogenising and extrusion
Each bar of soap starts at the batching stage. Our master Batch Makers are responsible for mixing ingredients according to each of our customers formulation specifications. Soap noodles are weighed according to a batch sheet and dispensed into a large mixer. Colours, fragrances and special additives are added at this stage to the batch.
Refining and Extrusion Stage
All of our soap bars pass through a process of triple milled, also known as French milled. Triple Milling of the soap homogenises and compacts all of the ingredients into ribbons of soap that give the soap bar greater lather and longer life. After milling the ribbons pass through the first refiner which is pushed through a mesh screen to further refine the base of any impurities. The soap then passes through a vacuum chamber which extracts air out of the soap to ensure that it is free of air pockets or streaks. In the final extrusion stage, a nose cone heats the soap billet to make it more pliable and perfect for pressing. An extrusion plate dictates the billets shape as it is prepared for the next stage.
Soap billets are cut into a shape that will fit the selected die using a Savoncut servo driven cutter with a high degree of accuracy. Cut billets move along on a conveyor belt as they prepare for the pressing stage.
At this stage a Stampex press compresses two portions of a soap die together, resulting in excess soap being squeezed out through a parting line around the perimeter of the bar. The unique feature of the press is the double stamp action from the internal gears of the soap press giving greater detail to the embossed images and shape of the soap bar. All Stampex pressed bars have parting lines, but they can be a high or mid-parting line, depending on the die used and the desired final result. Stampex presses are highly efficient as excess soap is recycled into the soap extruder and easily reused to make more bars.
All of Natural Resources soap base is sourced from Certified Sustainable suppliers and is of the highest quality material that offers superior lather and moisturising properties.
Production Bars sizes from 50g – 500g
Minimum Order Quantity: 600kg per type
Product Shape: Rough Cut, Rough cut emboss, Pressed.
Natural Resources Australia offers a wide selection of packaging options including:
- Bulk Pack
- Batch Coding
- Shrink wrap
- Paper wrap
- Stretch wrap
Please contact the team at Natural Resources Australia for further information.