There are 2 scenarios:
1.The anti-calc cartridge may have reached the end of its effective life or may have been exposed to conditions that have reduced its effectiveness. Please check the colour of the anti-calc cartridge and replace it if the colour has fully changed to brown.
2.Scale may have built up in your iron before you started using the IronCare water descale filter. You may need to descale your iron to remove existing scale first before your next ironing session.
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