Thanks for reaching out to Kent deboy!!! I'm glad they opted to provide a response, here are some follow-up thoughts...
1. The main ingredient in any brand of salt is sodium chloride. Sodium chloride is a mined mineral. It is NEVER 100% sodium chloride. It comes straight out of the ground and has different levels of minerals within it depending on where it was mined (even within the same quarry). A batch formula is made to the same measurements of ingredients every time and always assumes that each ingredient is 100% pure (which it never is). Each ingredient will have different levels of trace minerals in it. It is impossible to account for these discrepancies in production. This is the main reason why you see variations from one batch to the next.
Definitely understandable, and that's the reason I switched salts. Some of the more expensive brands use manufactured pharmaceutical grade components rather than salt collected via quarries or evaporation of NSW. The end result is higher purity. Here are a couple interesting links I've had bookmarked for a long while but never shared for some silly reason:
ReefCentral discussion regarding salt collection:
http://www.reefcentral.com/forums/showthread.php?t=1845009 - the takeaway, IMO, is that companies
should be testing for consistency and adjusting the mix accordingly
This link was taken down, so I had to pull it from an archive...but
this pdf is a MUST READ if you really are interested in comparing salts*: http://web.archive.org/web/20111128132714/http://aquariumwatertesting.com/AWT_Salt_Analysis_0208.pdf
When all is said and done though, if Kent is aware of the potential variability...why not address it? Not bashing, just a legit question. I could see a slight difference...but an alkalinity measurement of 7 vs 10 is significant. Why not make a batch of salt, measure the parameters, and adjust the salt? If that is a costly step (which I would assume it is), perhaps this is a classic case of "you get what you pay for".
2. Salt is a hygroscopic material that absorbs water vapor from the air. If you weigh out 35.5 grams of perfectly dry salt and dissolve it in 1 liter of water it should have a salinity of 35.5 ppt. However, since the salt normally has some amount of water in it, that is not often the case and the salinity will actually be lower because the absorbed water does not contribute to salinity. Adding more salt will raise the salinity but also raises calcium and magnesium levels. Inaccurate measurements of salinity are probably the second most common reason for differences in calcium and magnesium levels. If you are not comparing seawater made to the exact same salinity each time then you will have differences in calcium, magnesium, and carbonate hardness. Carbonate hardness is also pH dependent which can vary depending on the levels of dissolved carbon dioxide in the water.
This only addresses variances caused by mixing your salt according to volume (or weight) of water and the weight of the salt. If you mix using a calibrated refractometer...then your salinity wouldn't fluctuate and you should not be seeing these large differences. Unless I'm completely misunderstanding this...the fact is that I was measuring the exact same salinity each time, so why the differences?
3. Different minerals within the salt mix have different particle sizes and densities. The longer a bag or bucket has been around and shaken or vibrated will cause the particles to stratify. Smaller grain sizes tend to move to the bottom and larger grains to the top. Denser materials tend to move to the bottom also. This results in the salt taken from the top of a bucket having different values than the bottom. This is most common with calcium and magnesium. The lighter magnesium chloride tends to move to the top (as it starts out in a low density flake form before grinding) and the high density calcium chloride tends to move to the bottom (as it starts in a high density pellet before grinding).
And this is why it's always difficult to mix a small volume of saltwater for small water changes. You do end up with fluctuations between each salt mix that you make. However, I wasn't seeing variations between each mix as I was using about 3/4 of a bag each time I mixed my salt. I was seeing fluctuations between boxes...as many of us here were. Might as well reiterate that the salt I switched to says they pass all the minerals through an equal sized mesh, which (they claim) prevents the issue. I alluded to this earlier...but in the end that helps the problem, although it doesn't solve it completely due to particle density, which the rep at Kent pointed out. So that problem isn't entirely solved, but it's a step in the right direction IMO, and I've never had to roll my microbe-lift buckets more than once when I first get them.
The truth is that all of these variables have been occurring with all salt brands for decades and are perfectly normal and (except in extreme cases) not going to cause any noticeable difference in the aquarium. As long as the aquarium stays within a nominal range of values the animals and corals within will not be affected.
Magnesium and Calcium being "off the charts" is still a concern...for me at least. Sure they stayed consistent, but they were well outside of the range of NSW.
FWIW...I know a lot of people use Kent, have for years, and are extremely happy with it. I just had very mixed results with it, and gave it a year before I gave up and switched to another salt.
* That pdf I linked is from 07/08...haven't found a more recent version, but I may dig around and see if one exists. I'm sure many of those salt mixes have changed, but it should at least give you an idea of where some of the different brands fall. I'd still read it, but take the info provided with...a grain of salt. (badum dum tss)