One important question: Are you in a country where it’s winter? Have you stored your BTMS in a relatively cold storage environment? When BTMS is left for some time in a cold place, it will make it harder to melt. Not impossible, but harder. Here are some additional advice (I put a star in front of the ones that I would personally try first): Increase Heating Time: Please extend the time you heat the BTMS-25. It's crucial to ensure it fully melts, so consider using a double boiler and heat it gently and consistently. Chop your BTMS into smaller pieces + use a lid when you’re heating it. Monitor Temperature Closely: Use a thermometer to keep the temperature around 60-70°C (140-158°F) during the melting process. Maintaining a consistent temperature is key to successful melting. Gradual Incorporation: When adding the melted BTMS-25 to other ingredients, do it slowly and stir constantly. This helps in proper mixing and emulsification. Pre-warm Other Ingredients: Try to pre-warm the other ingredients in your formulation to a similar temperature as the melted BTMS-25. This can prevent the BTMS-25 from solidifying upon contact. Experiment with Smaller Batches: Smaller batches might offer better control over uniform heating and mixing, leading to a more consistent end product. If really your BTMS-25 never gives you satisfactory results, one last solution could be to switch the ingredient for BTMS-50, which is known to melt way more easily. But I’d do this as very last resort, as you mention, we don’t want to waste any of your precious ingredients. The reason why we didn’t make the original formulation with BTMS-50 is because this ingredient is much more conditioning and it can weight down hair, which we want to avoid. If you test with BTMS-50, try first with only half of the proportion of BTMS-25 that is recommended for your porosity.