Solid soaps
La Savonnerie des Alpilles crafts artisan soap bars using vegetable oils such as olive oil, coconut oil and sunflower oil.
Liquid soaps
Our liquid soap is made to the traditional Marseille method. This involves heating the ingredients in a large cauldron to create a soap paste. Our liquid soap is 100% plant-based and made mainly with coconut oil.
Cosmetics
The cosmetics industry has transformed, as consumers look to get back to basics and demand simpler beauty regimes. La Savonnerie des Alpilles is keeping up with this trend with our all-natural cosmetic skincare products: from body lotions, hand creams and shower gels to massage oils, face and beard care products.
Home products
From the traditional black soap made in cauldrons to the impressive stain-removing Savon de Marseille à la Terre de Sommières, our versatile products for the home clean, degrease, remove stains and make all surfaces sparkle.
Formulation
Developing a formula prototype
We create formulas according to our clients’ specifications and can even source new raw materials if needed. We develop the formula and run it through our R&D formulation software before subjecting it to laboratory testing lab tests also form part of the formula development process.
We create samples in our laboratory so we can carry out a full sensory analysis. We test a sample’s structure, stability, feel (lumpiness or roughness), texture, finish (dry or shiny), use and absorption. When we develop a formula for you, we also send the sample in your chosen packaging. All samples undergo internal checks before being sent out to our clients.
Regulatory testing
We carry out mandatory and optional testing both in our on-site laboratory and in an external laboratory. We begin by assessing the product’s stability over a three-month period, in a drying oven, in its final packaging, in the dark, at room temperature, in cold temperatures (4°C) and when exposed to the sun. We take an organoleptic (sensory) reading, assessing the look, odor and overall appearance of the product. We also measure its pH value before preparing a report on its stability. What’s more, we carry out patch tests to check the product’s skin compatibility and HRIPT tests for products that will be applied near the eyes. Everything depends on the toxicologist’s recommendations.
Meanwhile, a month-long challenge test is conducted in an external laboratory to check for preservative efficacy. The results of the test will determine whether the product meets the A or B acceptance criteria.
Lastly, optional user testing can be carried out with a panel of volunteers to assess the product’s performance. This testing allows us to validate marketing claims that will appear on the packaging.
Production
Once the formula is confirmed (after around six months for products manufactured on contract), we then schedule production. We start with a soap paste which is added to the mixers (we have two 200 kg mixers and one 100 kg mixer). Vegetable oils can be added as superfats while still cold in order to preserve their properties. Next, the soap is put through a triple roll mill before passing through an extruder, which compresses and shapes it into bars. The bars are cut and stamped in a press, or in a manually operated stamper for soap sold by weight.
At la Savonnerie des Alpilles, we have four soap presses :
- Automatic presses fitted with metal molds, for medium to large production runs
- Manually operated presses with spit molds, for small runs
Our workshop also offers several packaging options including :
- Automatic cellophane or paper wrapping
- Retractable film
- Sunray pleating
- Packaging in cardboard boxes
Regulation (EC) 1223/2009 on cosmetic products
La Savonnerie des Alpilles supports you every step of the way to ensure new products comply with European legislation. We can even take care of the administration: submitting formulas to the cosmetic product notification portal (CPNP), drafting the product information file (PIF) and coordinating laboratory testing.
