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On this week's episode of How Stuff Is Made, we look at how Lush's Godiva Shampoo bars are made. We take a tour of the Lush factory to see how this product is mixed and packaged. Watch the video above to see how this wrapper-free classic is made!

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Transcript
00:00Goodbye plastic. Goodbye waste. It's a new era of shampoo, not a second too late.
00:07Be good to the earth. Be good to your hair. While singing in the shower, totally bare.
00:15Luscious Godiva Shampoo Bar is a two-in-one bar that conditions and shampoos, made to keep your hair healthy
00:20and strong.
00:22These little guys do not require plastic packaging and are totally naked.
00:29The bar was named after the famed naked protest of Lady Godiva.
00:33The story goes that an English noblewoman rode unclothed through the streets of England to protest against unfair taxes.
00:41Legend has it that the only thing covering her lady bits during her ride was her long, luscious hair.
00:47Over the centuries, the story became known for this particular detail.
00:51And the protest of Lady Godiva and her long locks continues to be told to this day.
01:02The first step to making these shampoo bars is to make an extract from hibiscus flowers and olive oil.
01:08The dried hibiscus flowers are wrapped in a cheese cloth and left to steep inside a pot with olive oil.
01:14Olive oil can increase the tensile strength of your hair, which prevents breakage.
01:19It's also richly moisturizing, which leaves your hair looking shiny.
01:24While the extract is steeping, ingredients that will make up the conditioner in the shampoo bars are combined into a
01:29pot.
01:31Cocoa butter, shea butter, and capua soup butter are combined with a number of oils that act as natural conditioners
01:37to soften your hair.
01:41All ingredients are then melted down with the hibiscus extract until it forms a thick orange substance.
01:48The orange mixture is taken off the stove, cooled, and poured into a tray to be taken to the cooling
01:54room to harden.
01:56After being cooled, the mixture is cut into tiny squares.
02:00These cute little cubes are now conditioner.
02:04Now let's see how the shampoo is made.
02:07The shampoo portion of the bar contains whole dried jasmine flowers, gardenia extract, and a mixture of essential oils.
02:15Sodium lauryl sulfate is a safe surfactant that produces the rich lather that you use to clean your hair.
02:24In the mixing room, the sulfates, gardenia extract, and essential oils are poured into a large mixer.
02:31The gardenia extract is what makes the mixture yellow.
02:36After these shampoo ingredients are fully mixed, the chunks of conditioner are added and combined.
02:43The whole dried jasmine flowers are one of the last ingredients to be added to make sure they don't break
02:47during the mixing process.
02:53Periodically, the mixture is tested for consistency.
02:56It is important that it is firm enough to hold together.
03:05The final mix is taken to be pressed into bars.
03:11It often takes several attempts to get bars to the exact size and weight required for the perfect Godiva shampoo
03:17bar.
03:17It can't be too loose.
03:20It can't be too thick.
03:23It has to be just right.
03:262.5 centimeters thick, 5 centimeters in diameter to be precise.
03:31Although they may look small, these bars last up to 80 washes.
03:35That's the equivalent of 2 to 3 8 fluid ounce bottles.
03:43Once the bars are all pressed, they are packaged and sent to your local Lush store.
03:48Last year alone, just over 2 million plastic bottles were not manufactured because customers chose to buy Lush's solid shampoo
03:56instead of a bottled product.
03:59That's a lot of plastic that could have ended up in the garbage.
04:04So, if you're looking to be more environmentally friendly, or just want to shake up your shower routine, these little
04:10bars could be your new best friend.
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04:21See ya!
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