Hi Benjamin, thanks for inviting me. Nice read and it looks like oyu are having fun. A few comments/ notes I took:
Regarding your experiments with cook times and zap-testing. You are right that the longer cooks are not all about making zap-free soap. I do a one-hour cook because that is what works for me to make the soap zap-free (of course) but also to get the consistency I like. The consistency is also a factor of the water used, and the cook of course cooks of some of the water. Long story short, it's about what works for you and your process.
Glycerin - use it! I ended up using 11% of the oil weight in glycerin and that's on top of the natural glycerin I get form the other ingredients. I believe you will notice a very nice improvement in your lather.
KOH vs NaOH: I use 100% KOH and to my mind it makes a far superior soap. There are arguments to use varying levels of NaOH, mostly for hardness, but cooking and moisture levels will address that. Plus, I've never met a shaver that REALLY wished his soap formed a nice hard bar. We want to get it soft so it loads anyway. My soap is plenty hard to form pucks and soft enough to press with some effort into a bowl if so desired. Most of the time I package it in screw-top containers or tins anyway so I only rarely make pucks.
Now getting hard bar comes at the exclusion of moisture and cooking off moisture makes it hard to form as you have discovered. Using Sodium Lactate really helps with loosening up the consistency when it's hot, and then adds to the hardness when the bar is done. You might consider trying some of that. It's a real nice addition to the process.
You mentioned a couple times the color of the bar. The lather will always be white but the bar does pick up color, especially as you use fragrance oils that may contain vanilla. I use TiO2 (titanium dioxide) to help with that. I don't add much, a little goes a long way.
Finally some have mentioned EDTA to help with water minerals. This is a very good addition and it's helped with soap scum quite a bit. Even if your water is not bad enough to impact the lather, it still helps.
That was all I could think of as I was reading through. Looks like you are having fun, keep it up!
Regarding your experiments with cook times and zap-testing. You are right that the longer cooks are not all about making zap-free soap. I do a one-hour cook because that is what works for me to make the soap zap-free (of course) but also to get the consistency I like. The consistency is also a factor of the water used, and the cook of course cooks of some of the water. Long story short, it's about what works for you and your process.
Glycerin - use it! I ended up using 11% of the oil weight in glycerin and that's on top of the natural glycerin I get form the other ingredients. I believe you will notice a very nice improvement in your lather.
KOH vs NaOH: I use 100% KOH and to my mind it makes a far superior soap. There are arguments to use varying levels of NaOH, mostly for hardness, but cooking and moisture levels will address that. Plus, I've never met a shaver that REALLY wished his soap formed a nice hard bar. We want to get it soft so it loads anyway. My soap is plenty hard to form pucks and soft enough to press with some effort into a bowl if so desired. Most of the time I package it in screw-top containers or tins anyway so I only rarely make pucks.
Now getting hard bar comes at the exclusion of moisture and cooking off moisture makes it hard to form as you have discovered. Using Sodium Lactate really helps with loosening up the consistency when it's hot, and then adds to the hardness when the bar is done. You might consider trying some of that. It's a real nice addition to the process.
You mentioned a couple times the color of the bar. The lather will always be white but the bar does pick up color, especially as you use fragrance oils that may contain vanilla. I use TiO2 (titanium dioxide) to help with that. I don't add much, a little goes a long way.
Finally some have mentioned EDTA to help with water minerals. This is a very good addition and it's helped with soap scum quite a bit. Even if your water is not bad enough to impact the lather, it still helps.
That was all I could think of as I was reading through. Looks like you are having fun, keep it up!