mass producing soap

[ktaggard]

I was reading through candybee's - post where she asked how many bars of soap we make a year. How do some of you make so much soap? I just opened a shop a few months ago, and the soap production is killing me. What kind of molds and processes do you all do to mass produce your soap?

I bought a big mold from "For craft's sake", but massacred the 18 pounds of soap when I tried to cut into logs. Maybe I have to invest in professional cutters, but I'm on a tight budget.☺

Any tricks of the trade ???

[TallTayl]

Good tools, like cutters, really do help. I limped along with home/made bar wire cutters for years and held my breath every time i cut.

Time saver #1: dimension Standardization. When i had different bar sizes it made a huge bottleneck in production. Once i settled on a bar size i tossed every single mold that did not conform. It made packaging easier and everything cheaper.

Time saver #2: formula standardization. I have soap friends that have basically a different formula for each scent. Truly, that would drive me batty making and as a customer. What if i don't like tallow but it is the only way i can get the scent i want? How do i know which scent has which ingredients???

Time saver #3: going bigger. The biggest mold i use is 12" wide by 24" long. It makes 4 22" long logs cut with a home made single wire splitter with a platform to help keep it from wiggling as i cut. I have been meaning to add 3 more wires so it cuts all the logs in a single pass.The first log splitter i used wiggled and made some interesting log dimensions.

The mold i use most is 10"x12" and makes 20 lbs/48 bars. It's easier to use than the 24" for sure! When making super small batches to market test, i use the 11 inch tall skinny nurtures. I can fit 4 in a large flat rate box to saponify, stacking them to take very little space.

I looked at the for crafts sake blocks and decided they did not suit my soap style. If we change to non-decorated tops i will look at them again for sure since pouring one batch in that size would save even more time, especially since i would not have to hang around to texture the tops.

Time saver #4: preparing oils and minimizing the number of measurements. Most of the time spent soap making is measuring the darned oils, Pre measuring the oils in batch sizes, or master batching all oils in one giant pail to use in a single soaping session really helps. Pail warmer belts, drum warmer belts and such really cut time. When the oils are ready, it takes less than 15 minutes to pour 100 bars. Rinse, repeat, lol. One pail of organic sustainable palm makes 550 bars in my formula. A new pail of palm needs to be fully melted and mixed in one go, so i just make up all the oils at that one time.

Time saver #5: reducing scents. I am still working on this one. My summer faire offerings are at least 50 varieties at one time with 5 or so new ones rotating in each of the 9 weeks. Off-season, that list is cut to less than half of that. I wish i could cut to 10-12 total without inducing a panic attack! In truth, the scents that sell best in every product probably do amount to 10 or fewer. It would save me a TON of money and time to just make the cut.

[Candybee]

I hear ya about the scent cutback. Last year I cut back to 36 and decided that was still too much! I already have my 2016 lineup that I have cut back to 30 scents I will be offering. I want to cut back to 24 but it is sooooo hard to figure out which soap to cut out. I don't just do soap scents, each scent goes with a particular soap i.e.; salt bar, facial bar, shaving soap, scrub, castile, etc.

 

I just started masterbatching as it took all this time to finally get all the molds I wanted. And as TT pointed out, I learned mold conformity was exactly what I wanted so I had to wait until I got 4 molds the same size. They are all 18" long and make 18 x 4 = 72 bars. So now I can mass produce more on a scale that will help me a lot. For a long time I could not make soap fast enough because I didn't have all the same size molds. That was a pain because you can't master batch your oils or lye if the molds don't match. Well, actually you can but its a huge pain in the patootie doing it that way.

 

So whether you have several same size molds or just a couple large production molds like TT has that can make a huge difference in your production quantity.

 

Also, I may make a lot of different soaps but to help me mass produce them I have 3 sets of scents for each type soap. So now I can make all 3 doing a masterbatch of oils and lye solution. Then all I have to do is add the right fragrance or other additive to each individual soap batch.

[puma52]

I am amazed at how much product you all create in such little time. I admire you all.

[emilyspoppy]

I truly hope that my comments I write in this posting are received in the "friendly light" in which they were written. My intentions are to compliment my colleagues and in no way impugn their talent as crafters or competent business persons. I do, however, want to offer something for anyone interested in this business to consider;

I'm confident that Shannon and Candy are two of the more successful and accomplished soapers on this board. I've personally communicated with them by phone and have enjoyed sampling and using well made products from both of them. I'm also confident that they have a loyal and potentially expanding customer base. Their output of product makes my meager venture into this world of soap and even candles, pale in comparison.

I just did some quick math, however, and came to a puzzling if not troubling concern of how much bottom line profits are really available to the home crafter when you view the scenario in the cold terms of an actual and honest P&L viewpoint.

I doubt that anyone will argue that even these very talented producers could not sustain even a modest livelihood solely in this business. That's not my main point, however. What concerns me is truly how much we're making in income when we really add up all of the hours we spend at this and truly factor all of our expenses into the equation.

It becomes evident, at least to me, that unless this is a true labor of love, our time would be better served as a greeter at Walmart.

[Candybee]

Depends on how much product you are making and how well you price, market, etc. Soap is not the only product I make so it is a portion of my sales. I also make solid lotions, lip balms, lotions, candles, etc. My problem is I am only one person so I am always looking for ways to streamline my production in both quantity and quality.

[TallTayl]

Lol, poppy. That is very true, which is why i changed my business model from craft shows to one big annual multi-weekend event that draws 300,000 people in my niche market. I had to stop making loads of 10 bar batches in favor of one 100 bar batch. My time is my most precious and limited resource.

It took an awful lot of time to find my niche and build the return customer base, one willing to spend more $ in a visit than a customer kicking tires over a single small$ item. Believe it or not i have had to "fire" a few bigger wholesale customers to regain profitability and sanity. Also had to have the guts to stop making so darned many things. It is so tempting to make scrubs, lotions, etc when you already make soap.

I've had to change the Etsy store too. I rely on etsy income to pay for a few specific things.Too many samplers eat away at any hope of profit. The min transaction to make it worthwhile is $20. After the time, COGS and fees that is breakeven.

Profit also grows with strategic raw material buying. I can't make $ using ingredients from typical retailers like BB, WSP and the like, especially in small amounts. They are geared toward hobbyists looking to recover a little $ to make more soap, not someone needing to live off the proceeds.

Many times i have looked around and thought i should just close up shop. I could work a local job and profit the same with a fraction of the work and no aging inventory. But then i remember why i started the business and keep on keeping on.

[emilyspoppy]

I'm certain, as I stated, that both of you are the best at this, but I know how much you have to give-up to do it, too.

I belong to another group that's very active and virtually each day some member who has just started out on this journey writes how they are planning on starting their own business in order to quit their "other" job.

I'll be 66 next month and I started selling candles at the ripe old age of 25. I've only been doing soap as a side feature for a few years now and M&P at that. I love some aspects of this, but despair at others. I will always craft candles and soaps for my own use and as gifts, but I'm really contemplating how much longer I will continue to do this "professionally".

My point to all of this, as I wrote, is friendly. I know my sense of humor isn't always evident and mainstream, perhaps a bit too sarcastic, but it is meant to illustrate to those silent lurkers and perhaps newbies on the board to consider what this business really offers in terms of income potential before diving-in headfirst.

Just something to think about as we start another "day at the office".

Edited August 6, 2015 by emilyspoppy

[TallTayl]

I know exactly what you mean poppy

Until you actually dive in to the numbers you never realize how thin the margins really are.

Anyone can make soap/candles/{insert item here}. It takes a clever person to MARKET and actually SELL them and turn a profit.

[emilyspoppy]

I know exactly what you mean poppy

Until you actually dive in to the numbers you never realize how thin the margins really are.

Anyone can make soap/candles/{insert item here}. It takes a clever person to MARKET and actually SELL them and turn a profit.

YEP! And then some!

[chuck_35550]

Well CB said  it perfectly. Being  just a single with no employee help is a huge problem. I can make the product but there's no one in line to finish up the details except me. I have one wholesale account left to get out of and then its back to selling to a small customer base. Retailers know next to nothing about my products and therefor can't or won't help a customer to choose the best product for their need. I would love to be in a complex of handcrafters to share expenses and present the right purpose of handcrafting to the public. The large venues like the one TT mentions are very expensive, exclusive and require a huge amount of product. I gave up on three day festivals a long time ago (who can compete with funnel cakes?) and found a better profit margin selling to reliable customers. I have very little waste and my only headache is buying a fragrance that winds up a loser. I have way too many bottles in the lab that are duds. Buying in bulk and making a one of a kind product is the only hope I have for a profitable side business. But look, no matter whether you're in entertainment, service industry or handcrafting; nobody gets big  and rich overnight. Ten to twenty years of testing, hard work and natural talent make the end  result of a challenge the sweet reward. You can't discourage the person's belief system that they can come up with a new next thing. Handcrafting will never disappear as long as people desire something personally made with love.

 

Steve

[Candybee]

I actually like being a small handcrafted business. Also, this is not my only income as I collect SS. Believe me I've tried living off the income and although I can survive on it it's not enough for me to live worry free. But since I do have a steady income I use my small business as my $$ livelihood which works out for me. I absolutely love doing what I do and love my customers and their feedback.

 

Last year I lived off my biz income and it was really tough. It can be done but it is also very hard. That was when I finally came to realize that in order to make my biz profitable and live off the income I would need to become more of a factory than a one person manufacturer. Also, like TT, I would have to look for larger selling venues and that meant huge product volume including all that goes with it like buying in much larger bulk direct from warehouse, and seriously larger thousands $$ venue fees, etc. Sorry but that just isn't for me! Maybe someday but I really don't want to burn myself out or end up feeling like a robot!

[TallTayl]

Our biggest obstacle to our business being all we want/need is our big old But. It is comfortable. It is reliable. It is ours. We own it. We all have one, usually many. And we tend to let THEM define OUR limits. This was a humongous life lesson and game changer for me personally and my business,

I would sell on Etsy, BUT there are already so many people on there.

i would sell More on Etsy, BUT my pictures/tags/descriptions/labels/whatever stink.

I would eat healthy, BUT i love cookies and ice cream for breakfast, lunch and dinner.

i would make more XYZ, BUT....

The problem is not the But, but rather what you do about it. Take control of your But and become whatever you wish to be.

[Candybee]

Well said! I know I am very lucky in that I am doing exactly what I wanted to be doing for so many years. I love being my own boss and doing this full time. I love making soaps and stuff and earn money at it. I could go all out and get bigger but its not what I want to do.

[emilyspoppy]

YEP!

A labor of love!

Dave

[TallTayl]

Well said! I know I am very lucky in that I am doing exactly what I wanted to be doing for so many years. I love being my own boss and doing this full time. I love making soaps and stuff and earn money at it. I could go all out and get bigger but its not what I want to do.

So your But is you would grow bigger, but you don't want to so you don't. you took control and i bet it feels awesome!

Growing when you don't want to sucks all the joy out of the craft.

[chuck_35550]

My real fantasy would be to find a person or group of persons all into making soap. Bouncing ideas and areas of expertise would be such a joy. Customers can make critiques but its not the same as a couple of people involved in the process as it occurs. Writing music can be very much like that, with people throwing around ideas and coming up with something new and exciting. I wouldn't care if it was just a small batch or a huge batch, as long as it was a process that created a challenge that is shared. I show my wife some new technique and she thinks that's nice but it would have been cool for her to have been in the lab saying, "why not add this or that or don't you think that would look better?". Maybe someday.

 

Maytag Soapmaker

[Vernie1]

Wow, these comments are very interesting. I guess our crafting business is what we make it but it still lends me to ask, Is Wholesaling Soaps worth it?

 

I'm asking because I see some of  you have closed some of your wholesale accounts. I'm sure it's for different reasons but I'm about to venture out into wholesaling and wonder if it's even worth it.

[TallTayl]

Wholesale can be worth it, sure. Just make sure you have solid terms and limits to what you will do, along with high enough minimums.

[Candybee]

I still do wholesale but have a limited amount of accounts. You have to be careful with your pricing and know what soaps you carry in stock year round for it to work. If you can't get your soap costs down and still make a profit wholesaling its time to rethink it or wait until you can.

[emilyspoppy]

I have a good friend that I've known for years who is a member of this board. I first "met" her on another board and told her about this one. I hope she doesn't see this post or if she does she doesn't reply to it "publicly". I love her to death and she is a very gifted, generous and intelligent crafter. However;

 

Every time we communicate she tells me how busy (overwhelmed) she is and how little free time she has for "herself". She not only makes and sells candles & melts, she produces bath & beauty products including CP soap.

 

This information may not be current or completely accurate, but she's told me that she does a few shows and has a small retail set-up in her home that has separate access from her living quarters, but the bulk of her production goes towards her wholesale customers base.

 

She's told me numerous times that she loves making products for resale. So for her this is "A labor of Love". I've asked her if she's happy with her "bottom-line", but she seemed a bit "hazy" when replying.

 

I know that some (most?) of us might exaggerate our sales a bit and complaining about being "overworked" is nothing new for mankind (womankind?) either, but in her case I tend to believe every word she tells me. Which include;

 

She uses fragrances from a number of suppliers. I've asked her whose and she's told me some of her favorite FO's come from sellers like Brambleberry, Sweetcakes and others to mention just some that come to my mind right now. I suggested that some of her supplier's oils are too expensive for someone trying to generate a profit even though they do smell nice. They may be fine for a person making small quantities of soaps for personal use, but not for resellers I really don't think she understood me and I know she didn't agree with me.

 

Virtually every time we talk on the phone she is rushing to complete and ship wholesale CP soap orders. I've asked her how much she prices her bars for and she told me; $2.50 retail and I believe; $1.50 to $2.00 wholesale.

 

When I suggested that her prices were too low (several times) she told me that she felt they were consistent with the competition in her area (several times). She told me the retailers she sells to need to sell them for $5.00 to $6.00 per bar in order to make it worth THEIR while.

 

Since I don't do CP, I actually have no right to "beat-up" my pal over her business strategies, but I still and will continue to believe she's selling her time, her talent, her liability, her income and ultimately herself short.

 

I might be completely wrong. I don't know, but I've been in business a long time at a number of levels and everything I was taught and learned on my own "screams" at me that unless you are willing to make genuine sacrifices for a crafting business, your time might be better served as a greeter at Walmart.

 

(Geez! It seems that I've heard or read that somewhere recently. Oh, Yeah! It was me. You do lose your short-term memory as you become elderly!  . . .Now what was the point I was trying to make?)

[Guest OldGlory]

What a great conversation. I love all the replies, each and every one, and I am grateful to be part of this thoughtful and thought provoking  community.

 

As a wholesaler, I really struggle with retail. And I know the ins and outs of retail like I know the back of my hand because I was in retail management for most of my adult life (and I'm old, lol). I know retail well.

 

But as a wholesaler, I find this business type to be much more streamlined. I've been with one client (with 9 stores) now for 10+ years (had others along the way) and I know which products they will order from month to month, just not how many. About once a year I send them a new fragrance or a new style jar, I ask them if they want to add a new item to their lineup, and the answer is no or send us some samples. I usually get 11 orders a year with the slow time in January and February. For some reason this year they were hungry for more from me and they added 60% more new items.

 

What I don't like about retail is never knowing which fragrances will sell, how much to take to the event, setting up, tearing down, and taking home the items that didn't sell. And what do you do with the leftovers? I found that I did not make much money that way.

 

I make less money per item as a wholesaler, but I only make what is ordered. No leftovers, no loss of money/inventory. So in the long run, I think wholesale is way more profitable!

[Candybee]

Wow! $2.50 retail for a bar of soap is very low. I don't know anyone that sells that low. ANYWHERE!!!

 

I live in a country area and handcrafted CP soap goes for $5 to $7 a bar and this is a rural area and not a big metropolitan area. In NY a bar can go for up to $14 for artisan CP soap and does!!

[TallTayl]

WHAAAAAT? $2.50 RETAIL? She is super busy because she is underpricing herself. No way you can turn a profit with those numbers. By the time you figure in sales taxes, COGS, waste, etc it would actually be cheaper to hand out $1 bills.

[Vernie1]

Thanks everyone for the awesome feedback, it really is thought provoking. I ponder wholesaling vs. retail and actually did math to try to figure out if it will be worth my time. I certainly could not and do not retail my soaps at 2.50, I simply cannot afford to. This lady really loves what she does to retail soap at that price and love her wholesalers.

 

 

You all have definitely given me food for thought in regards to wholesaling and retail. OldGlory brings up good points in not wasting product or having scents no one likes or wants.

 

 

Emilyspoppy, you are a mountain of wisdom being in business for over 30+ years. I totally get what you mean!

Edited August 11, 2015 by Vernie1