When the crutching is completed, the soap is allowed to drop into frames through the valve at the bottom of the crutcher and rapidly crutched by the hand in the frames to prevent large air spaces and then allowed to cool. It is an improvement to jolt the frames as they are drawn away as this tends to make the larger air bubbles float to the surface and thus reduce the quantity of waste. When the soap has cooled, the frame is stripped and the soap slabbed as usual. At this point a layer of considerable depth of spongy soap will be found to have formed. This of course must be cut away and returned to the kettle. The last few slabs are also often rejected, inasmuch as the weight of the soap above them has forced out so much of the air that the soap no longer floats. As a fair average it may be estimated that not more than 50 to 60 per cent. of the soap in the kettle will come out as finished cakes. the remaining 40 to 50 per cent. being constituted by the heavy crust in the kettle, the spongy tops, the bottom slabs and scrapings. This soap is of course reboiled and consequently not lost, but the actual cakes obtained are produced at a cost of practically double labor.
It is advisable to add a small quantity of soap blue color to the mass while crutching to neutralize the yellowish tint a floating soap is liable to have.
Some manufacturers add a percentage of carbonate of soda, about 3 per cent., to prevent the soap from shrinking. Floating soap may also be loaded with sodium silicate to the extent of about 5 per cent.
It is not a simple matter to differentiate between toilet soaps and various other soaps, because numerous soaps are adaptable to toilet purposes. While some soaps of this variety are manufactured by the cold made or semi-boiled process, and not milled, the consumer has become accustomed to a milled soap for general toilet use.
The toilet base most extensively employed is a tallow and cocoanut base made as a full boiled settled soap. The manufacture of this base has already been outlined and really needs no further comment except that it is to be remembered that a suitable toilet soap should contain no great excess of free alkali which is injurious to the skin. Cochin cocoanut oil is preferable to the Ceylon cocoanut oil or palm kernel oil, to use in conjunction with the tallow, which should be a good grade and color if a white piece of goods is desired. The percentage of cocoanut oil may be anywhere from 10 to 25 per cent., depending upon the kind of lather required, it being remembered that cocoanut oil increases the lathering power of the soap.