Provided is a process for forming a personal care article comprising producing a personal care article from a twin screw extruder employing blowing agents, the personal care article including (i) from about 10% to about 60% of one or more anionic surfactants, wherein the one or more anionic surfactants have a Krafft point of less than about 30° C. (ii) from about 10% to about 50% of one or more water soluble polymers (iii) from about 1% to about 30% of one or more plasticizers and (iv) from about 0.01% to about 40% water. The personal care article has a density of from about 0.05 g/cm3 to about 0.95 g/cm3.
