The fees are getting pretty high on small transactions. i have a faucet that pays my members with block.io min 25k satoshis does that mean every payout i make they will reduce a fee this high ? need to find a solution for that ..
Can you just confirm that I've understood the question here? You are running a faucet with a minimum payout of 25k sats and using block.io as your wallet to send out those payments individually.
Does block.io make off-chain payments to the clients who also need a block.io account?
If not and it's sending blockchain transactions, then is it possible to send a multi-output transaction from block.io? That is, send different amounts to many recipients in one transaction. If that is possible then you will save a lot on tx fees as they are calculated per byte and you will not be duplicating most of the transaction data.
Also, I would recommend switching to a segwit capable wallet. Electrum is ahead of the game on this one, you can use native segwit with bech32 addresses. This gives ~10% saving in size over other segwit implementations that already save ~30-50%. You can upload a multi-output transaction into electrum from a CSV file.