This is where Willow Way, LLC can help. Once you have established the main system components, it is easy to step up production and volume without having to make major, formula, method and equipment changes.
The last thing you want to do is change your production methods every time your needs increase. With a Willow Way system, going from 600 bars per day to 1,200 bars or 2,000 to 4,000 is a snap!
Why these materials and methods?
First off, we have extensive experience in wholesaling, CP, M&P, Liquid and HP soap. Producing large quantities forces you to invent and experiment. We have tried it all and the resulting processes and materials won out time and again.
Why don’t you use wood?
Won’t last; soaks up oils and retains contaminates, wood breaks down. It is grainy, splinters, warps, and is difficult to clean.
Why not use silicone liners or molds?
Silicone is expensive to replace. It tears and breaks down over time. It can shrink if not taken care of. It retains scent and must be washed periodically. Silicone does little good on large block pours since soap sticks to about everything. Overall, to the Professional SoapMaker it is inefficient and not cost effective.
Why not sheet plastic liners?
In the long run, it’s slower and sometimes costly. We tried this too but found that they still require a method to hold them in place, and soap had to be scraped off between pours. Wrinkles can occur, soap can slip in behind and lift them out into the pour, ruining entire loaves of soap.
Why not Plexiglas?
First material we tried. Cracks over time due to the oils affecting the molecular structure of the Plexi. To weak for large molds.
Why not larger tray molds?
Very labor intensive. Top layer of ash has to be scraped off, hence lots of waste, tricky to pour right depth, hard to move right after pour. Poorer saponification than block molds. Per bar, a tray mold is double the cost, both in the initial mold cost and in the production and waste lost.