I have worked with Steam A Seam since it came out. What you have is a bad batch or one that was hanging on the shelf way too long. This product does have a shelf life just like Heat n Bond, Wonder Under and the rest. Put what you have left back in the pkg and take your scissors with you to return it. I have only had this happen to me once but it sure was a mess. Out of all of the brands, this one has worked the best. Heat and cold do affect it though so keep that in mind when storing.