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We Proudly Manufacture Bar Soap in the USA
At Twincraft Skincare, we know bar soap. We’ve been making it since 1972, and we are proud to be the contract manufacturer of choice for any brand that wants to bring superior triple milled bar soap to bathrooms nationwide and around the world. At our Winooski, Vermont headquarters, we conceptualize the best bar soap for face and body, and our large team of over 250 employees turns a brand’s vision into a beautiful, high quality final product.
For over 45 years, we have led the industry in innovation and sustainability, and prioritize natural developments. Every brand that we work with has their own natural standards, and we are flexible to work with your needs and concerns. Natural colorants, recyclable packaging, sustainably harvested active ingredients, coconut oil soap base, RSPO certified palm oil soap base, and a solar powered manufacturing facility are all aspects of our bar soap business available to help our customers make sustainable bar soap products with unique aesthetics that will resonate with today's consumers.
To explore custom bar soap development with your own Twincraft team, please contact Sales.
At our primary manufacturing facility, we finish bar soap, which means that we purchase soap base from several of the leading soap base providers in the world. We mix in various additives – fragrances, colorants, active ingredients, and other materials for visual aesthetics – and refine the ingredients into the base, extruding and pressing the result into finished bar soap.
Our process for extruding bar soap is highly efficient and produces consistent bars that last much longer than a poured version. Many years ago, Twincraft manufactured poured bar soap for a select group of customers, but this was not a scalable or efficient way to make bar soap, so we focused our efforts on offering extruded bar soap options that to provide the best possible quality products to our customers, and to consumers.
While we extrude 100% of the bar soap that ships out from our facility, we are able to manufacture products that feel unique, featuring aesthetics that replicate hand-poured techniques and artisinal qualities.
We are inspired by poured soap trends, especially as they relate to popular natural ingredients, and our innovation team is always working to develop new manufacturing techniques to replicate the hand-crafted look and feel that attracts premium bar soap consumers.
We are able to achieve a hand-cut look that mimics the shape and feel of handmade varieties, and have the capabilities to imprint bars with random logos, textures, and indentations. We are also able to combine soap noodles with the base to give a swirled effect that we refer to as a "galaxy bar," which can also be interpreted as a tie dye aesthetic.
Through coextrusion techniques, we are able to achieve a layered look, combining multiple bases with different skincare benefits into one unique bar concept. We showcased this technology in our luxe bars, which replicated the layered look of geodes and minerals like quartz with sustainable glitter additives.
There are Four Stages of Bar Soap Manufacturing
Bar soap finishing as we do it can be broken down into four primary stages:
1. Batching Stage
2. Refining and Extrusion Stage
3. Cutting Stage
4. Pressing Stage
Each bar soap that we finish starts at the batching stage. A Batch Maker is responsible for mixing ingredients according to our lab’s formulation specs. Soap pellets are weighed according to a batch sheet and dispensed into a large mixer. Any dyes or titanium dioxide is also added to the batch, and color is tested against an agreed upon standard before adding remaining ingredients.
Refining and Extrusion Stage
Our bar soaps pass through a process that qualifies them as triple milled or French milled, depending on the marketing claims a brand would like to use. The first refiner extrudes the soap base through a mesh screen to break the batch down into soap ribbons and the second refiner pushes the ribbons through another mesh screen. The soap passes through a vacuum chamber, which pulls 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 outside of the soap slug to make it more pliable and perfect for pressing. An extrusion plate dictates the slug’s shape as it is prepared for the next stage.
Soap slugs are cut into a shape that will fit the selected die using a Uni-Cutter. Cut slugs are moved along on a conveyor belt as they prepare for the pressing stage.
Bar soaps that are made here at Twincraft are pressed in one of two options: a condor press or an STU press.
A condor press compresses two portions of the shape together, resulting in excess soap being squeezed out through a parting line around the perimeter of the bar. All condor 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. Condor presses are highly efficient as excess soap is recycled into the soap extruder and is easily reused to make more bars.
An STU press utilizes a soap slug that is cut to just under the length of the desired shape, and pressed in a ring to the weight of the finished soap. STU pressing results in very little excess soap, and will always have a solid band around the perimeter of the bar where it was formed in the ring.
Our bar soap customers have two packaging options for their products: in-line packaging or staged wrapping.
In-line packaging occurs immediately after bars are pressed; finished bars are placed on the line and packaged by machines in their respective wrap, including cartons, paper wrap, flow wrap, or in a bulk pack.
Stage wrapped bars are moved from our pressing room to our wrapping room where they are placed in a crease wrap, sollas wrap, paper wrap, tissue wrap, or shrink wrap.
While soap finishing is an efficient and sustainable manufacturing process, there is always some soap waste after a production run. Instead of sending this soap to a landfill, Twincraft Skincare donates it to Clean the World, a social enterprise focused on improving hygiene and saving lives through education and soap donations.