Cardboard Tubes as soap molds
I wish I had read your message earlier today because I just cut two tubes of soap this evening and would have taken pictures to demonstrate how I do it. Next time...
Okay, here is what I do to prepare the cardboard tubes. First, I take the empty cardboard tubes (used to package scotch - I get them from the local liquor store) and saw off the bottoms with a hack saw. (Takes about 45 seconds per tube).
Then I cut squares of parchment paper to fit the tubes: an 11 1/2 in square piece is perfect. (About 90 seconds per square.)
I then put the squares of parchment into the tube, smooth it out so that it fits, and secure the ends with Scotch tape. It's a little tricky because even tape has a hard time adhering so parchment. Once the ends are secured I seal the seam with a long strip of tape. I put one end on a wood spoon and feed it through the tube, When I have both ends in my hands I can carefully start at one end and secure the tape over the seam. I use the wooden spoon to burnish the tape down over the seam on the inside of the tube. (About 90 seconds per tube.)
While I'm doing this I'm melting parafin in the top of a double boiler. When the was is melted I pour about a quarter inch into the bottoms of round, Pyrex 10 oz. dishes, then insert one end of the lined cardboard tube into the wax. The 10 oz. dishes fit the cardboard tubes perfectly and, once the wax has melted, the glass dishes provide stable base that keeps the tubes upright. (About 30 seonds per tube.)
When my soap is at trace I pour it directly into the tubes, then cover each tube with foil.
24-48 hours later, I make a small slit in the top of each cardboard tube and start peeling it back. The cardboard tubes have a spiral seam and, once you find that, the cardboard peels off easly. If the soap is still a bit soft I set it aside to cure for another 24 hours before cutting it into bars. Cutting is pretty straight forward: I lay a metal ruler on each tube of soap and score it lightly at 1 inch intervals as a guide. Then I cut the bars using a chef's knife. I keep of large pot of near-boiling water on the stove to dip the knife into after each cut. This keeps the blade clean and the knife, when kept hot, cuts the 3 1/4 inch tubes of soap more easily.
The Pyrex dishes are re-usable, as are the discs of wax left over after the cardboard is peeled away. (I wash the wax discs thoroughly in cold water, then set them aside until I'm ready to prepare more molds.) I get the cardboard tubes for free so it's a very economical set up.
As for packaging, I will take pictures of that tonight to show you exactly what I do.
Jaaret.
