Pro Polymer Lumping Issue in Formulation with Propylene Glycol

The reason your Pro Polymer formed small, clear lumps is likely due to insufficient water in the formula and the presence of a high concentration of Propylene Glycol interfering with the polymer's hydration. Pro Polymer (Acrylate Crosspolymer) needs enough water to swell and form a gel. When water is limited, or when ingredients like high concentrations of glycols are present, the polymer particles can clump together instead of dispersing and hydrating properly.

In your original formula, the water content was relatively low (46.8%). When you added the mixture containing 40% Propylene Glycol to the water/Pro Polymer phase, the high concentration of Propylene Glycol likely hindered the Pro Polymer's ability to hydrate fully and evenly, causing it to form lumps.

The staff's suggestion to increase the water content and change the mixing procedure addresses this issue. By ensuring sufficient water and allowing the polymer to hydrate in the water phase before adding potentially interfering ingredients, you can achieve a smooth gel texture.