soap-formulation

name: soap-formulation description: > Expert soap recipe formulation, troubleshooting, and educational guidance for cold process (CP), hot process (HP), bar soap (NaOH), and liquid soap (KOH). Use when the user asks to: (1) formulate or generate a soap recipe, (2) troubleshoot soap problems ("why is my soap soft/crumbly/not lathering/getting DOS"), (3) substitute or compare oils, (4) review or improve an existing recipe, (5) get formulation advice on fatty acid balance, superfat levels, or additive choices, or (6) learn about soap making chemistry and techniques. Do NOT use for melt-and-pour soap, syndet bars, or cosmetic regulatory questions. compatibility: Requires soap-calc Python package (pip install -e .) metadata: version: 1.0.0

Soap Formulation Skill

Before You Start

If the user's request involves formulation, chemistry, fatty acid selection, additive choices, or troubleshooting soap behavior, read references/soap-formulation-expert-reference.md first. It contains condensed expert knowledge on fatty acid profiles, additive interactions, and formulation archetypes.

If the request specifically involves superfat oil selection, HP post-cook additions, DOS/rancidity prevention, or oxidation stability, also read references/superfat-guide.md. It covers superfat tradeoffs (stability vs. sensory vs. lather), base-superfat interactions, and stabilization strategies in depth.

Skip the reference files for simple requests like "make me a soap label" or "write product descriptions for my soap line."

The soap-calc Package

This project contains a full-featured soap calculator. Use the package tools instead of doing manual calculations. The package handles SAP values, lye calculations, property estimation, and validation — all from its built-in oil database.

Key Project Paths

• Oil database: data/oils.json — built-in library of common oils with SAP values and fatty acid profiles
• Additive database: data/additives.json — common soap additives with usage rates and notes
• Example recipes: examples/ — reference recipe files
• JSON Schemas: schemas/ — validation schemas for recipes (recipe.schema.json), oils (oils.schema.json), and additives (additives.schema.json)
• User extensions: Oils can be extended via ~/.soap_calc/oils.json

CLI Commands

The soap-calc command is available after installing the package (pip install -e .).

• Use --oil-weight {grams} with calculate or export to override the recipe's default oil weight.
• Use -o {path} with export and scale to write output to a file.

For Python API usage and writing recipe files, consult references/api-guide.md. It includes a schema-driven workflow for generating valid recipe JSON/YAML from schemas/recipe.schema.json.

Workflow: Generating a Complete Recipe

When a user asks you to formulate a recipe, follow this workflow:

1. Consult the reference file for formulation guidance and archetype selection.
2. Search the oil database — run soap-calc list-oils or use search_oils() to confirm oil names and verify SAP values are available.
3. Write the recipe file — follow the schema-driven workflow in references/api-guide.md. Save to the examples/ directory or the user's requested location.
4. Validate the recipe — run soap-calc validate {file} to check for issues.
5. Calculate the recipe — run soap-calc calculate {file} to get exact lye, water, and oil amounts.
6. Export if requested — run soap-calc export {file} -o report.md to generate a printable recipe sheet.

Never manually calculate lye amounts when the package is available. The oil database has verified SAP values. Use calculate() or the CLI to get exact, safe lye figures.

Recipe Output Format

When generating a soap recipe, always include:

1. Oil blend — list each oil with percentage of total oil weight
2. Fatty acid profile summary — approximate % lauric, myristic, palmitic, stearic, oleic, linoleic, ricinoleic
3. Lye type and amount — specify NaOH or KOH (or both), calculated at the stated superfat %
4. Water amount — as ratio to lye (e.g., 2:1 water:lye) or % of oil weight
5. Superfat % — and rationale for the chosen level
6. Additives — with usage rates (% of oil weight or tsp per lb of oils)
7. Process notes — CP or HP, expected trace speed, temperature guidance, cure time
8. Expected soap properties — hardness, lather type, cleansing level, conditioning, longevity

Lye Calculation Rules

• Use the soap-calc package for all lye calculations. The built-in oil database has verified SAP values.
• If an oil is not in the database, say so and recommend the user add it to ~/.soap_calc/oils.json or verify with an external calculator (SoapCalc, Soapee).
• Never present an unverified lye amount as safe. Incorrect lye = caustic or lye-heavy soap. This is a safety issue.
• Always state the superfat % used in the calculation.

Safety Callouts

Always include safety notes when generating recipes or process instructions:

• Lye (NaOH/KOH) is caustic — gloves, goggles, ventilation required
• Always add lye TO water, never water to lye (exothermic boiling risk)
• Soap batter and fresh soap are alkaline and can irritate skin
• HP soap reaches 170–200°F — burn risk from hot batter
• Recommend pH testing or zap testing before first use of any new recipe

Tone and Audience

• Default to practical, confident guidance — assume the user has basic soap making familiarity unless they indicate otherwise
• For beginners, add more process detail and explain "why" behind choices
• For experienced makers, focus on formulation rationale and tradeoffs
• Use the mental models from the reference file to build intuition, not just rote rules

Common Request Patterns

"Help me formulate a soap for [goal]" → Read reference file. Start from the closest archetype recipe, then adjust fatty acid targets to match the goal. Write a recipe file, validate it, and calculate it with the package. Explain tradeoffs.

"Why is my soap [problem]?" → Read reference file. Map the symptom to likely causes (e.g., soft bar → too much oleic/not enough palmitic/stearic, or insufficient cure time; DOS → high polyunsaturates + no chelator/antioxidant). For DOS/rancidity specifically, also read references/superfat-guide.md for oxidation system analysis. If the user provides a recipe file, run soap-calc validate and soap-calc calculate to get concrete data.

"What should I use for superfat?" / "Which oil for post-cook HP?" → Read references/superfat-guide.md. Match recommendation to the user's base oil profile (high-lauric, high-stearic, high-oleic, or high-PUFA) using the base-superfat strategy table. Recommend from Bucket 1 (high-impact, stable) by default. Flag stability concerns for PUFA-heavy picks.

"What oil can I substitute for [oil]?" → Use soap-calc list-oils to look up fatty acid profiles. Match by fatty acid profile, not by oil name. Two oils with similar fatty acid breakdowns are interchangeable.

"Review my recipe" → Run soap-calc validate and soap-calc calculate on the recipe file. Check fatty acid balance against the targets in the reference file. Flag if cleansing is too high (>20% lauric+myristic without high superfat), if polyunsaturates are risky (>15% linoleic+linolenic without chelator), or if the bar will be too soft or too hard.

Examples

Example 1: "Make me a gentle beginner bar soap"

1. Read references/soap-formulation-expert-reference.md — select the "gentle face/baby" archetype as starting point, adjust toward a more balanced everyday bar.
2. Run soap-calc list-oils "olive" and soap-calc list-oils "coconut" to confirm exact database names.
3. Write a recipe file using the schema-driven workflow in references/api-guide.md (read schema, reference example, generate, validate).
4. Run soap-calc validate recipe.json — fix any warnings.
5. Run soap-calc calculate recipe.json — present lye/water/oil weights.
6. Offer to export: soap-calc export recipe.json -o report.md.

Example 2: "Why is my soap getting orange spots?"

1. Read references/soap-formulation-expert-reference.md — identify DOS (Dreaded Orange Spots) as rancidity from high polyunsaturates.
2. Read references/superfat-guide.md — analyze both layers of oxidation risk (superfat pool + soap matrix) and base-superfat combo stability.
3. If the user provides a recipe file, run soap-calc calculate and check linoleic + linolenic totals.
4. Recommend: reduce polyunsaturates below 15%, switch to a stable superfat (Bucket 1 or 2), add a chelator (sodium citrate at 0.5% of oils), add antioxidant (ROE or vitamin E at 0.5% of oils). Reference additive details in data/additives.json.

Example 3: "What can I use instead of palm oil?"

1. Run soap-calc list-oils "palm" to get the fatty acid profile of Palm Oil.
2. Match by fatty acid composition (high palmitic/stearic/oleic): tallow, lard, kokum butter, or mango butter are common substitutes.
3. Run soap-calc list-oils "tallow" etc. to confirm database names and compare SAP values.
4. Explain the tradeoffs (e.g., tallow is closest but not vegan; kokum butter is harder but more expensive).

Inventory-Aware Formulation

The project includes an Inventory Management skill (skills/inventory/SKILL.md) that saves a validated inventory.md file listing the user's available oils and additives.

Only use the inventory when the user explicitly asks. Look for phrases like:

• "use my inventory" / "from what I have"
• "make a recipe with my oils"
• "formulate using my supplies"

When inventory is requested:

1. Find the inventory file (priority order):
   • Check ./inventory.md (current directory) first
   • Fall back to ~/.soap_calc/inventory.md (user default)
   • If neither exists, tell the user they need to create an inventory first
2. Constrain oil and additive selection to items listed in the inventory.
3. If the inventory doesn't contain enough variety for a good recipe (e.g., no hard oils, no lather booster), tell the user what's missing and suggest additions.
4. Follow the normal formulation workflow otherwise (consult reference file → validate → calculate → export).

If the user does NOT mention their inventory, ignore inventory.md entirely and formulate from the full database as usual.

What This Skill Does NOT Cover

• Cosmetic regulatory compliance (FDA, EU cosmetics regulation)
• Melt-and-pour soap (different process entirely — no lye handling)
• Syndet bars (synthetic detergent bars — not true soap)
• Commercial-scale manufacturing processes

For these topics, answer from general knowledge or recommend the user consult specialized resources.