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Traditional Aleppo soap is made by the "hot process". First, the olive oil is brought into a large, in-ground vat along with water and lye. Underneath the vat, there is an underground fire that heats the contents to a boil. Boiling lasts three days while the oil reacts with the lye and water to become a thick liquid soap. Soap cooling
Small scale artisan soap makers find "melt and pour" production useful when trying out new product lines. The process differs from the cold process or hot process in utilising a pre-manufactured solid soap base which has already undergone saponification, so the soap maker does not need to handle caustic alkali, i.e. lye.
"Hot process" soap making also uses lye as the main ingredient. Lye is added to water, cooled for a few minutes and then added to oils and butters. The mixture is then cooked over a period of time (1–2 hours), typically in a slow cooker , and then placed into a mold.
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In Syria, soap was produced using olive oil together with alkali and lime. Soap was exported from Syria to other parts of the Muslim world and to Europe. [37] A 12th-century document describes the process of soap production. [38] It mentions the key ingredient, alkali, which later became crucial to modern chemistry, derived from al-qaly or "ashes".
Soapmakers frequently use rebatching as a way of adding substances that could not withstand the high temperatures or caustic chemical environment of cold process or hot process soapmaking, such as certain essential oils (for example, those with a very low flash point). The choice of liquid affects the character of the finished soap; milk is ...