When we first started making bar soaps we went with using molds for forming each bar. They were much easier for us to produce small quantities and present a very neat solid shape. We took a new approach to our bar soaps with our re-launch last Spring. The thoughts were to give them a hand made look by forming a loaf in a mold to then hand cut for individual sell-able units. This process was also thought to make the process faster and the ability to produce more bars at once. Our sales had increased enough that we needed to make a dozen or more at a time to be efficient.
We sourced loaf molds and cutting boxes and went to work producing our new bars. They were a hit right away. People loved the fragrances as much as the look. Behind the scenes we had a problem; consistency. The loaf molds were not perfectly square and would bulge in the middle from the weight of the soap. When cutting the bars we found wide variations in the weight of each bar. The cutting process also caused minor fluctuations in thickness as well. And, there was a lot of waste from trimming off the edges. Those trimmings were able to be re-batched, added to the next production run so not to be a total loss.
It is very important for us to maintain consistency as much as possible in weight or volume of our products. We still hand craft everything we sell, so there is bound to be some minute inconsistencies but these bars were varying 15 to 20 grams within a batch. Our call was to mark them at the lowest average weight. We also came to realize that the hand-crafted look is not what we want. Despite being hand crafted we still wanted to keep a smooth “produced” look to our products, knowing that as we grow it will be the natural aesthetic by default.
When we launched our shampoo bars we decided that the round molds would be best. Making it an ideal size and shape for user experience. If molds were good for the shampoos then they should be good enough for the body bars.
It became apparent that the changes we made were not the right step for us and decided to return to forming each bar in its own mold. This allows the polished edge to 5 of the 6 sides of the bar. The bottom side, which is the top side when pouring into the mold, would not have a perfectly smooth surface. We are OK with that. Having an “unfinished” side to the soaps supports the “natural” nature of our products. Having one rough side versus 6 rough sides.
By using a mold for each bar gives us consistency without any waste. The variances are minimal, with each bar being at or above our target weight. There is less labor involved, no cutting up a loaf is needed just pop the formed bar out of the mold, smooth edges and bag. We are migrating back to using block molds for each bar as we replenish inventory. New inventory is already in stock, we will get new images up to reflect the changes as all our current options convert.
With increased growth we are able to tighten up our presentation, to put forth a more polished look so we can truly put reflect a premium image along with out already premium products.