Lol, yep. I try to get rid of all the loose pieces beforehand but it's not 100% effective, sometimes one or two will stay behind & show up on me later. However, it's not nearly as bad as it used to be before I took to shaking the loose pieces out. What I used to do when that happened I'd just shake out some flies into an empty deli cup, add a small amount of 50/50 powder mix* to coat the flies & keep them from escaping then use my feeding tongs to remove any loose bits of excelsior that fell in. I could take my time pulling the pieces out since the flies weren't going anywhere. But yes that was still a pain so I now I do my best to make a ball consisting of only long strands of excelsior to add to the culture so I don't have to pick pieces of it out everytime I need flies.
Hopefully your experiments go well and you find a solution that works a lot better.
*powder consists of a mix of 50/50 honey powder & bee pollen. (I think I originally bought some from MantisPlace.com but its not hard to make your own, I had to put it through a coffee grinder a couple times to get the powder fine enough for this purpose.) Then you shake the cup to coat the flies in the powder and it weighs them down so they can't climb out of the cup. I don't even need a lid or to keep tapping the cup to keep the flies in, they just stay at the bottom of the cup on their own, it's like magic. I learned this trick from a video about making ff cultures for frogs but they used calcium powder which mantises do not need so I tried to find something to coat the flies in that would be better suited to a mantis & happened across this supplement, I believe it's called Yen Saw's mix.