I am gonna be the devils advocate and say that i think it may be something not addressed so far on this thread,the Pigments...
I use Silmar, and the mica from coastalscents and haven't had any blending issues at all. I use around 10 drops MEK per that it says on the can. I can mix my colors, add MEK, stir for one to three minutes, and pour. then i put them in the pot and pressure it up on the same table as the pancake compressor that i use. the shaking, and the early pour seem to have little effect. In fact, it is a fun thing to play with for me...
if i mix, and pour immediately, the colors blend slightly on the edges and the seperations fade a bit... but if i wait a few more minutes before i pour, the seperation is very strong. I also am not that accurate with my measuring. i pour the PR into little silicone muffin pan thingies.. then add color with a popsicle stick. then i add the MEK to about how many drop i think it should have. I only go in measurements of 5 with the drops.. weird huh???
I would simply have to do a pour or two with less MEK and see the results, but for what it is worth, i think it might be the pigments..