Bald Guy: this is a bit off topic. Have you ever considered using pieces of heat sealed soda straws to hold your flare innards? I use this to hold cotton-petroleum jelly tinder. Perhaps the flare material would ignite better. If so, I may try putting a pair of strike anywhere matches (probably just the head + 1") in the top of the straw before sealing.

How readily does the flare material light a) with a match and b) with a spark?