aferac, I don’t know what material your molds are made from, but like you, I’m a SUPER long-time wearer of HAs.
I am highly allergic to the clear plastic or pink-tinted so-called “hypo-allergenic” ear molds. Both times I trialed these molds, I ended up with otitis. I can tolerate the shiny, flesh-colored molds, but no longer wear that model of ITE aid. Luckily, I’m not allergic to the soft silicone double-dome tips, so that is what I have on my Phonak Lumity Life speakers.
Even the custom, firm, clear, silicone molds cause my ear canals to flare RED, itch and burn like the dickens. If that isn’t an allergic reaction, what is?
So try either a different material of mold, or forget the mold and go with a soft, silicone dome. Mine are a dark topaz color cuz my audi told me that a few patients were allergic to the clear domes!
Hope you get this sorted out… but definitely put NOTHING in the ear canals if possible till all the redness is gone.