The Hot process
The method used to produce Aleppo soap properly is a type of hot process which has been used for centuries and has remained largely unchanged during that time. No intensive machinery is used, just the ancestral knowledge of the locals who refine their skills over years of graft!
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The production process begins with the addition of olive oil, water & lye to a large vat built into the ground.
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An underground fire then heats the content to a boil for 3 days.
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During this time, the olive oil gradually reacts with the water and lye to form a soapy substance.
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After the 3 days have passed, laurel oil is added to the mixture. The quantity of laurel oil present in the final soap typically ranges from between 5% and 40%.
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The mixture is then poured over a large sheet of wax paper and is allowed to cool for half a day.
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During the cooling process and before the mixture hardens, workers with flattened planks of wood flatten out and smoothing the mixture to make the cutting process more effective.
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Once the soap is flat and the cooling process is complete, the soap is cut into cubes manually using a manned cutting tool.
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After the cubes have dried sufficiently, they are put into a special subterranean chamber to be aged for six months to a year. During this time, the moisture content of the soap breaks down, making the soap harder and last longer.