I spray and press on the wrong side of the fabric - so if it flakes a bit it doesn't matter. I like it when it feels like a sheet of paper, as that's when it cuts the best. Used to buy starch, add water and mix and soak my dad's fatiques in it, then iron it dry, as their uniforms had to be extremely crisp when wearing them. Don't think I'd want to go to that length now, but that might be the solution to your problem. Its cheap to buy, and will really make a crisp fabric. One thing to think about though -- if you're having this much trouble with it now, will it hold up in your finished quilt like the rest of the fabrics? I'm thinking probably not.....and it would be a shame to have areas of your finished quilt wear much faster or tear apart. Easier to switch out the fabric now and use a good quality one.