6 g/l on stage one?
Is that normal for you?
I'm with you on that one Glyc, that's an awful lot of NaOH & meth for a 150ltr batch 1st stage.
I'd be looking at a max of 4g/ltr and no more than 22.5lt of meth. and would expect around an 85% conversion.
I never use more than 3g/ltr and 15% meth for stage 2.
The more catalyst you use the more water you generate the more soap you get.