Round Soap Mold Using Poly Tubing

Here’s an efficient way to make large batches of round soaps. I posted several years ago about how I use poly tubing to create my shampoo bars. Denise Casperson in British Columbia, Canada took my idea a step further and I’m delighted that she wants to share her methods.

Benefits of Denise’s set-up: 1. pour at waist level to reduce air bubbles, 2. insulated to help force gel stage, 3. soap is protected and contained in case of a poly tubing mishap – which I admit I’ve had a couple!, 4. creates a smooth top = less waste.

Here’s what it looks like:

Poly Tubing Set-Up by Denise Casperson

Removable flange on bottom of pipe provides stability.

4 inch flat poly tubing produces a 2.5 inch round of soap.

(You can purchase 4″ tubing HERE.)

ABS bulkhead plumbing fitting; body with a 2.5 inch thread and a nut.

1. Once the poly has been cut to length, a knot or two is tied at one end, with the other end ready to attach to the fitting. As the threaded part of the fitting is same size as the poly, the poly is gently stretched and then pulled up over the threads. Ensure the poly hangs from the fitting in a straight manner. 2. The threads are quite coarse, so I put a layer of masking tape over the poly to protect the poly and to provide a tighter fit when the nut is screwed onto the body of the fitting (3).

Once the length of tubing has been attached to the fitting, the tubing can be lowered into the 3 inch pipe, with the bulkhead fitting sitting on the rim of the pipe. It is now ready for filling.

Once filled, the poly/fitting assembly is secure enough to lift/raise to check the progress of the soap.

With the 2.5 inch soap round inside of the 3 inch pipe, the poly mold can hang unobstructed, the soap is protected, insulated, and contained in case of a poly mishap.

Soap has gelled, hardened and is removed from the mold. As the fitting holds the poly open 2.5 inches all the way to the top of the ‘mold’, there is only minimal loss/trim at the bottom where it has been knotted.

Finished soaps!

Thank you, Denise, for sharing this wonderful tutorial with us!

Making Round Soap in Poly Tubing

If you’ve ever been frustrated at trying to get your round soap out of a PVC pipe, you might want to check this out. The idea has been floating around the soap blogs and forums for awhile now. Of course I heard about it right after I had just invested about $50 in a custom sized 2.5″ PVC pipe (the plumbing store would only sell me a full-sized stick), so I wasn’t overly anxious to go out and purchase more supplies.

Ok, so I got a little bit frustrated with the pipe. Even freezing the soap in the pipe, then pulling it out and letting it sweat wasn’t working every time. So two months ago I invested another $32.61 in some 2.5″ poly tubing. Hello. A 2.5″ flat tube is totally different from a 2.5″ round tube. Unable to send it back without incurring shipping fees plus a 25% re-stocking fee, I still have it. I let it sit there staring at me for about a month before I decided to go ahead and order the correct size – which was 4″ tubing. (Yes, 4″ flat tubing will give you about 2.5″ diameter soap.) And then life got busy.

Yesterday, I finally got around to making my Beer & Seaweed Shampoo Bars in the poly tubing. Hubby helped me with the set-up. I needed a way to prop the bag up and open while I poured the soap in.

Pipe fittings to hold the poly tubing, with a hole in the end of a board

The board goes all the way to the back of my supply rack, with a box half full of business cards sitting on top.

I had to stand on a chair to get to the top of the tube and pour the soap in! Also folded over a bath towel and placed it on the floor under the tube to catch any drips.

I taped the funnel to the top of the pipe fittings

I left the soap hanging there overnight. It was actually ready to cut about 18 hours after I poured. The tubing slid right off – success!!

Here are the cut bars:

Deep Patchouli Beer & Seaweed Shampoo Bars

Here are some of the differences that I’ve noticed between this batch and previous batches:

1. They definitely did NOT gel.
2. They have more air bubbles from pouring such a long way down.
3. They are exactly 2.5″ in diameter which is slightly larger than the ones I made in the pipe – pre-cure weight is at least half an ounce more.
4. I’m also short a full bar – partly due to the knot at the bottom of the tube, and partly due to the slightly larger diameter, but I can deal with that!
5. This was SO much easier! I have a batch of the Lemongrass Herbal Mint already poured this morning. This is definitely going to be the way to go for these soaps!

Here is what they normally look like:

Beer & Seaweed Shampoo Bars

Check out the updated tutorial for using poly tubing HERE.