Making Your Soap Bar Design Into An Exclusive Brand Name Product

Image of the Masterline Mold ShopThe Mold Shop has lots of room and space to work on your soap bar designs.
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You have selected the right type of soap bar, the right size and shape of your soap bar. You have submitted the artwork for your company name, logo and perhaps background or border artwork. 

The next hurdle is calculating the weight and then the dimensions of your soap bar. You will probably have questions and need help finding the right answers to calculating the weight and dimensions of your soap bar.

The standard soap bar is usually 3 inches by 2 inches by 1 inch thick. The standard soap bar contains (multiply 3 x 2 x 1 ) 6 cubic inches of your soap solution. A standard weight is usually 3 ounces or 90 grams.

So knowing your standard soap bar (3 x 2 x x) has 6 cubic inches of soap, but your soap bar weight is 3.25 ounces or 100 grams.

We better stop at this point and talk about package weight because in this case you have to adjust your soap bar dimensions for the packaging weight.

Importance Of Package Weight

When a soap bar product is labelled with a weight, let us say 90 grams or 3 ounces, the contents of that package must have at least the weight that is labelled on the package. Should the soap bar weigh little more than the package weight, that is acceptable to the labelling laws and FDA regulations.

It is when the contents (a soap bar) weigh less than the label weight, a company could face fines. It is a priority to get as close to the weight as we can, knowing there is a minimum the soap bar has to be, but not so much over that is costs more to manufacture the soap bar.

Adjusting the Dimensions of Your Soap Bar

In the example above, since the weight of the soap formula weighs more than the average, the dimensions will have to be adjusted.  In this case, having less dimensions will bring the soap bar to that 90 or 3 ounce weight.  We can adjust the length; we can adjust the width, and, we can also adjust the thickness.

Building Your Perfect Soap Bar Design

Picture of a Block Plaster being formed into a rectangle shape soap bar.
We do not use power tools, CNC, or 3-D Printers to form your soap bar. Every process is a hand-crafted method just as your soap bar is hand-crafted.
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​The next step is to highly polish the soap bar to eliminate any and all scratches on the surface of the bar. This is done using 'wet sandpaper'. Any scratches left on the bar, will translate in the final product even to the siliccone rubber mold. 
As we are building a precision soap bar, we use hand tools and several templates to check and re-check our progress. Using power equipment might be easier and faster but there is always the danger of creating hair-line cracks in the final soap model.
Picture of Newly Formed Rectangle Plaster Soap Bar
Newly shaped rectangle soap bar is ready for stylizing by creating stylized edges and corners and perhaps, adding a border.
Picture of a Newly Formed Oval Plaster Soap Bar with slightly rounded top surfaceA freshly designed oval soap bar with sloping top, full round edges. Oval soap bars continue to be popular.



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​A perfect soap bar design has been created. Next is to make another plaster mold of the top and sides. We can now engrave the lettering (into the surface of the soap bar, or embossed the lettering (on protruding on top of the soap bar.
Picture of a Circular Soap Bar Designed As a Shaving Soap
Shaving Soap Bar, round, square edges, with raised rim and engraved and embossed company name and logo



Pictures of the final plaster soap bar are now sent to you by e-mail, for your approval before proceeding. 
  • Calculating The Weight And Dimensions Of Your Soap Bar
​Before we begin, it is just a reminder that not all soap recipes are same and therefore will weigh differently. As a policy we do not ask about the details of your formula. But sometimes we need to look at the ingredients used in your formula.  The ounce volume of the oils will weigh more then water volume. The water in the formula will evaporate when bringing the soap to the trace temperature.  Also other ingredients added to the formula such as an abrasive (seeds, flower petals, bark, or an embedded toy for kids, all add weight to the soap bar.
​​To arrive at the correct weight of your soap bar, we have design choices such as rounded edges, rounded corners, or engraving into the surface of the soap bar to lessen the volume or weight of the soap bar. Some design choices may add volume or weight to the soap bar such as extra artwork, size of company name/logo on the surface and  also with raised borders, either a thick or thin border.
Free, no charge quotation by dialing
1-905-791-3559