When you make your 50% solution, I've found it helps tremendously to account for the water loss that occurs as you are mixing it up. The first time I made mine, I weighed everything before and immediately after mixing- including the mixing container and cover- in order that I could determine how much water evaporated off as I was mixing. It turned out that I had a water loss of 6 grams. I added that back in, placed the cover on and waited for it to cool off. Once cooled off, I weighed it again to make sure no more water had evaporated off (all was well). Then I pour it through a stainless strainer into my storage container.
The next time I mixed up a batch of 50% solution, I weighed out 6 grams extra water at the beginning, and when I weighed it at the end of mixing, it was a perfect 50% solution. Since then, I've made all my subsequent batches of solution with a 6 gram excess of water at the beginning and it all surprisingly evens out to a perfect 50% solution at the end. Just weigh everything before and after to find out how much water you're losing and add it back in when done mixing. And then doublecheck when it has cooled off.
It's normal for a 50% solution to be somewhat thick/syrupy (I'd actually be concerned if it wasn't). It shouldn't have flakes, though. If it does have flakes, it could be any of these things: Your mixing or storage container had some soap residue in it and the lye has reacted with it to form harmless soap flakes; it might be harmless sodium carbonate that has formed from the lye in the solution reacting with air (it doesn't dissolve, but can be strained out); it could be that the solution has gotten too cool and the lye has precipitated out (applying a little heat will remedy that); or there wasn't enough water present for the lye to stay mixed properly (just add a little more water).
As for flakes forming on the spout, this happens to me, too, but I've noticed they dissolve when mixed back into the solution. I usually see a few flakes on the cover to my container, too, and I've noticed that as the cover sits on my counter during the time it takes for me to weigh out my needed amount of solution, the flakes on the cover turn into liquid. That's because lye is very hygroscopic (attracts moisture in the air to itself).
HTH!
IrishLass