1 v 2 Step in Soap Manufacturing
POV: you're making the bar soap of your dreams, and a custom contract manufacturer starts saying this like "1 step" and "2 step".
What the? In the jargon-heavy world of manufacturing, where today's decisions will affect tomorrow's product, it can feel hard to keep up with these terms. 1-step and 2-step processes refer to the methods used to extrude, press, and package your bar soap. As the names suggest, 1 step is more streamlined, while 2 step is a slower process for soap with more aesthetics. But, as always, there's a little more to it. Information on 1 step and 2 step processes is oddly hard to come by. So we're breaking it down for you. Let's get into it.
1 Step
As the name suggests, 1 step bar soap goes from batch to finished-good pallet in one continuous manufacturing process. While all production lines have a minimum of 1-2 Production Operators, plus a Batch Maker, Process Tech, and Production Lead, 1-step productions require less interaction with the product and are handled only once. Because the soap is packaged right after being extruded, the bar is still warm as it gets packaged. Which can lead to nicks or scuffs. As the bar gets pressed, any residual material or rejected bar goes back through extrusion, so there's generally less scrap associated with this process. Formulas with lower moisture content, that are less prone to scuffing, or customers with less stringent aesthetic requirements, work well for 1-step runs. To that point, 1 step is a great option for a project that hinges less on bar soap aesthetics and more on volume output.
2 Step
The 2-step process describes separating the extrusion process and the packaging process. Rather than one continuous process, in 2 step, the bar soap cures before packaging. During this process, employees touch each bar twice to ensure the desired aesthetic is matched. Because of the closer attention to detail, there is a higher rate of scrap during the 2 step process because imperfect bars are not run back through extrusion, like they are during the 1 step process. After being pressed, the bars are placed in a temperature-controlled environment for at least 24 hours before being set up on a line for packaging. The 24-hour period is to allow the bars to cure. This interim period is best for softer formulas that might morph if packaged immediately. This time also allows for a final inspection of the bars. Because this path requires more time and labor, additional costs are often associated. The most common pack designs for bar soap are folding cartons and paper wrap; both can be achieved from 1 step or 2 step process.
The biggest variables to consider when choosing between a 1 and 2 step process are: goals on aesthetic and packaging. It's important to remember that just because your product is being run on 2 step doesn't mean each bar will be flawless, and similarly, running your product on 1 step does not mean each bar will be flawed.
Whichever path you choose, our team is here to make the bar soap of your dreams. Reach out to our Sales team to get started!
