Abstract: The invention provides a personal cleansing freezer bar comprising a skeleton structure having a relatively rigid, interlocking, semi-continuous, open, three-dimensional, crystalline mesh of neutralized carboxylic acid soap selected from the group consisting of sodium soap; wherein said bar is made by the following steps:(1) mixing a molten mixture comprising by weight of said bar: from about 15% to about 85% of said soap and from about 15% to about 40% water;(2) cooling said mixture to a semi-solid in a scraped wall heat exchanger freezer;(3) extruding said semi-solid as a soft plug; and(4) further cooling said soft plug to provide said personal cleansing bar.

Abstract: A method and apparatus for stamping a blank of plastic material, such as a soap blank, into a shaped article, such as a soap bar. The apparatus and method uses a pair of mating die halves spaced apart from one another in order to receive the blank of plastic material. Thereafter, the blank of plastic material is stamped and shaped by closing the die halves so they are mating. The die halves are then opened so as to discharge the shaped article and receive a new blank of plastic material. The present invention contemplates placing an elastomeric septum across each die half between the blank and the die half so as to prevent plastic material from sticking to the die halves after stamping. It has been found that a septum made from latex works well.

Abstract: The invention provides a firm, ultra mild, neutral pH freezer bar comprising: from about 10% to about 50% of monocarboxylic acid; wherein from about 20% to about 65% by weight of said monocarboxylic acid is neutralized; from about 20% to about 65% of an anionic and/or nonionic bar firmness aid, and from about 15% to about 40% water by weight of said bar;wherein said neutral pH is from about 6.3 to about 8.0;wherein the neutral pH freezer bar is made by the following steps:I. mixing a molten (170.degree.-205.degree. F.; 76.degree.-96.degree. C.) mixture comprising said carboxylic acid; water; and bar firmness aid; neutralizing said 20% to about 65% of said carboxylic acid, preferably with sodium hydroxide;II. cooling said mixture to a semi-solid in a scraped wall heat exchanger freezer;III. extruding said semi-solid as a soft plug; and further cooling and crystallizing said soft plug until firm to provide said neutral pH personal cleansing freezer bar.