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Char cloth is more ignitable when it's clean and supple. (My theory) For "cleaner"... I put a 1/4" vent hole in my char tin so that the gases can escape very easily. For "supple"... I place a buffer of punkwood on the bottom of my char tin which keeps the cloth from touching the red hot metal of the can. It provides for a more consistent heat. The heat must not fluctuate. If you let the char tin cool, even a little, after the gases have started venting then you will have some to all hard char cloth. This theory can easily be tested. The next time you make char cloth wait for the gases to start venting, take the char tin out, kind of like you would do when adding wood to the fire, then put it back in the. The char cloth usually come out with some degree of hardness.
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