CANNOT EVEN IMAGINE what you're doing wrong! For the past three years I buy Best Press BY THE GALLON! It is THE absolute best! I never have iron residue. If I'm having a brain freeze and have to take out stitching a couple times to the same seam, I use Best Press to put the sizing back into the fabric. I do as the instructions say; just spray and press. I'm sorry you're having a problem but, again, I cannot imagine what you're doing . . .