From Scraps to Suds: Let's Rebatch Together!

Reduce, Redo, Rebatch!

I recently forgot to add the essential oils to a batch of Spiced Pumpkin Porter beer soap. The soap was usable and chemically correct but didn't have those yummy scent notes of cinnamon and clove that make it feel so cozy to use on a chilly fall morning. Luckily, this was a very fixable problem. I have been making soap for 6 years now which has given me lots of time to refine my process as well as learn a few tricks to be more sustainable and save the odd oopsie batch! One of these tricks is called rebatching!

The Rebatching Process

Rebatching beer soap is my cozy day method for recycling production scraps and reducing waste. It's the process of grating soap or gathering trimmings to rehydrate them and melt them into a brand new batch of beer soap! It's a tedious but incredible process that allows me to be a better steward of my resources. While I used to see it as a chore, I have since come to love rebatching, finding it to be a comforting, mindless process that feels peaceful on low-energy days. 

What kind of soap scraps can be used?

• Trimmings + Shavings: After I make a successful batch of soap, I cut it into bars of a specific weight and shape. This always leaves behind some perfectly good trimmings and shavings that are too small or oddly shaped to sell.
• Imperfect Batches: Sometimes, a batch just doesn't turn out right. The batch of Spiced Pumpkin Porter that I forgot to scent is a perfect example. Instead of throwing it out, rebatching gives me a second chance to get it right!

I save up all the trimmings and imperfect soaps of a kind until I have enough to make a batch. Then, the real work begins! I get out my box grater (yes, like the kind you use for cheese!) and grate all the large pieces of soap by hand. I’ve tried just about every alternative—a food processor, a blender, even one of those zucchini spiralizers in a moment of desperation—but nothing works as well as the classic box grater. If you've ever grated a few pounds of hard cheese in one sitting, then you understand how tired my arms can get. But hey, at least I'm building some muscle from it...

Water, Heat, and Time

Once everything is grated, it all goes into a heated pot with a bit of distilled water. This rehydrates the soap and allows it to be mixed again once the heat softens the scraps. It takes 3-5 hours at around 200°F for the soap to melt down to the right consistency and texture. I mix it at least every hour and add more water as needed to prevent it from burning. Once the soap is about the same texture as mashed potatoes, it is ready. The rebatching process can cause any of the scraps' original scent to evaporate. At this point, I can add more fragrance if necessary and pour it right back into my soap molds. There it will harden over a couple days like any other batch of hot process soap.

I always laugh when asked if my soap will melt in a hot car or a window display. The answer is a definite "no!" It takes a lot of shredding, time, consistent heat, and intentional effort to melt down a high-quality bar of made-from-scratch beer soap. This is not your basic melt-and-pour kit soap. Leave it in your car for the long road trip! In fact, my car started smelling so good from driving to and from my art markets that I started selling these soap sachets just so everyone's car could smell as good as mine all the time!

Whirls, Patterns, and Textures

But the coolest part about rebatching? It can create some seriously cool looking soap! While some batches are indistinguishable from my original beer soaps, others have a unique mosaic pattern that I love even more! It’s a tangible reminder that slowing down and savoring a little extra hard work often results in something even more special and sustainable. Totally worth it!

Cheers,

Elaine

Spiced Pumpkin Porter before the rebatch

Spiced Pumpkin Porter after the rebatch

Want to try my sustainable soap for yourself? Whether you want the best soap for dry skin or the best soap for oily skin, you can find a beer soap for your exact needs! Check out all the options in my shop!