I've been reading this more frequently lately. My current puck is probably beyond 1/2 life, but hopefully the spares I've accumulated are older stock - I'm too lazy to dig them out and look for any batch numbers (if any).You might be onto something here.
I have hitherto been a big fan of MFW and have never had any issues with lathering. I recently 3017'd a puck and it performed flawlessly (as has all previous pucks). However, this new puck I'm working with is beginning to really test my patience...
The lather is airy, thin and simply refuses to develop into the glorious lather it should. It's still slick as hell but it just dissipates. Alas, no matter what I try, it flat out refuses to play ball.
I have exactly the same problem. never had an issue with the first puck, which lasted 1 1/2 years. this new puck is unusable no matter what I do, and I have done everything. I am using it as a pre shave soap. I won't buy it again.
I order mine from Connaught Shaving which has the lowest price (even with shipping) and stellar customer service.
This is where I picked up my MWF ceramic kit; packed superbly it was...
I just tried it again today with a brush on the dry side and a 2 min load but I only managed one decent pass. it feels like if you add any water the lather gets destroyed when you put the brush down because the water gets sucked up into the base of the knot and not released onto the face and it overwhelms the lather left in the knot. The trouble is getting the soap into the back of the knot when it has a serious glue bump that prevents the splay at that point. This hasn't been an issue why synthetic.
Bottom line is still that if your synthetics work best with MWF, just keep using them. If you do want to try again with your Zenith boar, based on my experience, you definitely need a well soaked brush to start followed by 45 seconds or more of loading time. Not sure how you store your MWF but if it's in the MWF ceramic container that much loading may be a challenge due to insufficient vertical space. I place mine in a 4" high plastic container for loading/proto lather development (photo below).
Yeah, it has to be a water issue or something. The bleached Zenith is just too difficult to get a good lather with consistently. I've tried less water and more water in the knot before loading and I'm barely able to get two good passes with a 2 min load. I'll keep at it for a little longer to try a few more things out, but the bleached Zenith is too soft to properly pick up enough soap without being overwhelmed by the lingering water in the knot. Still no issue with other knot types tho.
I prefer to use my boar or synthetics for MWF
I don't think I've come across this yet, so I will post my recipe for an almost perfect lather:
Use a shaken, yet semi-damp brush and load heavily into a lathering bowl.
Start to build the lather in the bowl to where it's almost usable but still a bit wet.
Squeeze out the brush into the bowl and load the residual from off the wet puck.
Take this loading and build directly on the wet face; dipping into the bowl-lather to add moisture and desired structure.
This will easily create 6-8 passes on a 26mm boar or T3 synthetic - zero frustration