Nearly all KOH on the calculators is used at a 90% purity level. This is because KOH is so hygroscopic, i.e., it attracts water like crazy.
I suggest you increase the water to lye ratio; that is, if the calculator is telling you 30% lye to water ratio, drop that down to a 25% lye to water ratio and see how much more workable your soap will become. I had to do that with my dual lye shaving soap because I use a 3" x 24" PVC pipe mold for making pucks.
The saponiCalc calculator defaults water/lye percentage at 33%, try adjusting it to around 25% and see how it works. My dual lye recipe uses a 22.22% lye to water percentage or a 1 to 3.5 ratio. Yes, adding more water will increase the need for more air drying after saponification, but it also greatly increases the workability of the traced batter to make it be able to pour into molds or spoon into individual molds. Take my word for it... it works very well. I sell my soaps also, and have had no complaints... yet. Also, the sodium lactate I add helps to improve the release of the product from the mold when the soap has completely cooled and solidified after about 20 hours or so.