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December 01, 2021
We love that feeling of fresh, new soap. The mix of texture, lather and fragrance creates that wonderful sense of everyday luxury. Too often, that feeling only lasts for the first few uses before normal soaps become just, soap.
At Natural Resources Australia we use traditional French Milling methods to create a beautiful, luxurious, but most importantly, long-lasting soap bar. This requires a 4-step process: Batching, Refining, Cutting and Pressing.
We start at the batching stage. Our master Batch Makers are responsible for mixing the finest ingredients sourced sustainably around the globe. Soap 'noodles' are weighed according to a batch sheet and dispensed into a large mixer. At this stage we concoct the magic with the addition of premium ingredients including hues, fragrances and textures.
All of our soap bars pass through a triple-milling process, also known as French milling. This homogenises and compacts all of the ingredients into ribbons of soap that give the soap bar greater lather and a much longer life. After milling, the soap ribbons pass through the first refiner which is pushed through a mesh screen to ensure the soap is free from 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 shape of the billet as it is prepared for the next stage.
After milling, soap billets are cut into a shape that will fit the selected die using a Savoncut servo-driven cutter to ensure each bar is the perfect size and weight.
In this final stage, our industrial press compresses two portions of a soap die together to create the final soap bar. The pressing stage adorns the bar with ornamental designs on the exterior, but also completes the shape of the bar such that it feels perfect to touch.
All our Wavertree and London soaps go through this rigorous process from start to end, so that once it reaches your hands, you can touch, smell and feel the quality. And that feeling will last throughout its lifetime.