Dave,
I use an H&S Evolution CR Plus. I was getting a similar thing to you and it was driving me insane. I, at the time, was working in the same pressure range as you with a 0.2mm needle as standard (to force the paint through the small gap). Nowadays my standard setup is 0.4mm at 15psi max, sometimes only 10 psi.
The reduced pressure and increased nozzle size aid in:
- reducing tip drying
- reducing resultant clogging of the nozzle
- reducing overspray
- reducing air drying
- reducing "spider" formation
You will have to have your AB closer to the model, though.
I must confess that I am unfamiliar with the abbreviation "MLT" but if it includes the words Levelling Thinners then that's spot on :thumb2:. I would echo the sentiments above that the thinner ratio should be upped to at least 50%.
As an addition, I am really against hype and the latest fashions but I have found a marked improvement by migrating to MRP. The Tamiya paints are really good (I have plenty of them :smiling3

but the MRP paints perform markedly better and the issue you report, coupled with the amended AB settings, has been eliminated. The AB settings and thinner ratio should be more than enough as a minimum though!
Happy spraying.
John