Carolyn -- it's your experience and ideas that are encouraging me to go lower in superfat. Having tried some of your soaps, I can say they are quite nice. I doublechecked my last soap and it was at 4% superfat, adjusted for NaOH at 97% purity. It turned out well, and I will have no reservations about doing the recipe again at 3-4% SF.
"...Low and behold it's 96% minimum. Yet another "ballpark" figure to work with. Since it says "minimum" that leaves a 4% variable...."
Yep. Although I'll add some more to that to further confuse the situation, based on my experience as an engineer in chemical production. If the allowable purity for a chemical happens to be 96%, we would run the chemical production to produce 97-98% purity. That gives a cushion against a little variability, but, frankly, there's no point in shooting for better. It can be surprisingly difficult and expensive to run a chemical production facility to produce a product that is significantly more pure than the reasonable minimum.
Also keep in mind that that this 96% purity is for the material that is coming out of the manufacturer's door. When we get NaOH, it has been repackaged by the distributor into smaller containers and we open those containers a number of times in our soap kitchens as we make various batches of soap. All that handling causes some water vapor and CO2 to enter the container. NaOH ~will~ react with that water and CO2, thus lowering the purity a wee bit here and a wee bit there. By the time the NaOH hits the soap pot, I would bet the purity is not any much higher than the minimum on the certificate of analysis. By the time the last of the NaOH is poured out of its container, the purity is possibly even a bit lower.