Many bar soaps are processed using continuous processing technologies, including single and twin screw extrusion. However, in spite of the industrial importance of the extrusion-based processing of bar soaps the rheological behavior of bar soaps is poorly understood. Here, the shear viscosity and the formation of gross surface irregularities upon extrusion of the bar soap were investigated using steady torsional, rectangular slit, and capillary flows. Furthermore, the structure development aspects were investigated using wide-angle X-ray diffraction and scanning electron microscopy. It is revealed that the flow and deformation behavior of bar soaps is complicated by the ubiquitous presence of wall slip, viscoplasticity, gross surface irregularities, and various structuring aspects. The orientation of crystallites and the shear stress dependent fracture of a crystalline component of the formulation at the wall during flow were identified as some of the contributing effects to the development of the structure of the bar soap during flow and deformation.