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I love doing gel cards and have received a few from people. I just went through my stack and the bags are all poofed out full of air and the gel seems to be coagulated and one of the cards the gel was like rock candy...
Any ideas on why this happened and on how to make them NOT do this?
The gel does decompose over time and releases the air contained in all those little bubbles. If there is a way for air to get in the bag, it's possible that it will dry up as well. If you are making them for samples and want to go to the trouble, you can take the card apart and put a new bag with fresh gel to keep your sample looking fresh.