I agree with everyone else, your starch is too heavy. And there have been a lot of hints about the flakes, I can't help you with the iron or the board cover, but I can with the flakes. The fast way to keep from getting flakes is before you iron, just take your hand and run it over the surface you just sprayed. It will eliminate the flakes on the fabric. quick fix. The iron if I have a problem I clean before I put it away that way it doesn't build up and the cover its buy a new one lol... Problem solved aren't I good lol....