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Actually, I just wanted to know if you had a Toro 40" because there is nothing that can be done to prevent it from clumping. I returned mine and got a 36" to solve the problem.
Now with yours you could try some gator blades. When I had clumping problems with my 40" I tried some Toro Atomic blades (they are notched like the Gator blades) and it helped a little bit. I can't say for sure it will work but it's worth a shot.
I have a few friends who cut with their chute removed, or up. It will eliminate the issue, but then you have damage to worry about. I only lift my chute when needed, and when I do I always make sure I'm pointed away from windows and doors.
I hear good things about gator blades, never tried them though.
One of the properties I mow weekly i have this problem. Come to find out they have a irrigation system. Had no clue about it till I showed up at noon today to cut grass and it was wet and had not rained.
2009 Exmark Lazer Z AS 48" 20 Hp B&S
Little Wonder walk behind edger (from 1960's)
Weedeater hedge trimmer
Royobi 4 cycle trimmer/edger
Redmax TR2350S trimmer
21" push mower
2002 Ford Ranger
Just starting out...