I can't believe that did it... I'm at 40/20 with new soap and all seems good.Green is a color, but not a surfactant. I'm telling you, the whole problem could be the soap mix. I have seen many a bad pail in the past. Chem manufacturers screw up too...
Assuming 40 psi is 40 psi (as in your guages aren't lying to you) you should be able to adjust up the foaming air to 10 or 15 psi less than the product pressure. If it's sputtering, you either have a chemical problem (as mentioned above) or you need a foam generator.
Can't believe I had a batch of faulty soap. Thats never happened to me before...
Also didn't realize how faulty soap could cause an issue like that!