Organisation
Soapworks Ltd
Sector
Manufacturing / Engineering
Knowledge base
University of Glasgow
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Challenge
Soapworks Ltd is the largest UK manufacturer of soaps and cleansing bars for body, hair, and face, producing up to 50 million bars annually and serving 50 global brand partners ranging from . luxury global fragrance brands, innovative start-ups and multiple UK retailers Following increased demand for eco-friendly and sustainable alternatives, Soapworks set out to diversify into synthetic detergent (syndet) bars.
Syndet production posed significant technological challenges due to high sensitivity to temperature, pressure, and moisture, resulting in reduced output and inconsistent product quality. The company lacked a dedicated R&D department with the necessary scientific expertise, prompting a partnership with the University of Glasgow to investigate production difficulties and embed evidence-based, data-driven problem-solving.
The KTP aimed to:
- Optimise syndet production using computer simulations, lab experiments, and practical trials.
- Improve product quality, efficiency, and consistency.
- Equip staff with scientific and data-driven skills to foster innovation.
Outcome
The project delivered substantial benefits for Soapworks:
Operational and technical impact
A suite of integrated rheological analysis tools, underpinned by Dr Manlio Tassieri’s i-Rheo methodology, was developed to unify production and material-testing data, identify optimal processing windows, and enable a design-for-manufacture strategy. These tools dramatically increased syndet efficiency reduced labour costs, and cut energy consumption
A novel broadband rheology technique, discovered during the project, provided Soapworks with patent-pending intellectual property, enabling cost-effective process optimisation and laying the foundation for potential commercialisation in the rheometer market.
Cultural and strategic impact
The KTP fostered a culture of innovation, established an R&D division, and strengthened university-industry ties. It inspired the Daabon Group to launch inter-company knowledge exchanges, including collaboration between Soapworks and Daabon’s Colombian plant, demonstrating the value of expert-led global knowledge sharing.
Associate impact
Dr Simeon Skopalik transformed the Associate role, combining scientific expertise with leadership and strategic vision. He integrated new modelling software with experimental data, developed process optimisation tools, secured funding for student internships, and facilitated international collaborations. He also achieved Chartered Engineer status, PRINCE2 certification, and became co-inventor on a patent application, exemplifying the qualities of a Future Leader.
Impact
The KTP has established Soapworks as a leader in syndet soap production, delivering significant efficiency improvements, improved product quality, and commercial advantage. It has empowered staff with scientific and analytical skills, embedded a culture of innovation, and created a foundation for global collaboration and potential new revenue streams through patented technology.
What they say
“In a new world driven by sustainability and resource conservation, the rise of solid shampoos and PH neutral cleansing bars opened up a new and fast-growing category using syndet base. Soapworks quickly entered this market, but the processing of this material was a significant challenge which in our fastest growing category was a major issue. Soapworks and the industry lacked the scientific knowledge on how to optimise the process and therefore we sought to partner with academia and Glasgow University on a KTP. Over the period of two years the project only mastered the production process and the impacting variables to facilitate an environment where products can be designed for manufacturing efficiency as well as efficacy. The project also delivered on some very exciting IP patent applications. The collaboration and dedication of those involved in the project was outstanding and really was an eye opener as to what can be achieved when industry and academia approach the same problem seeking to find a mutual solution.”
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