Thanks for taking the time to reply here lads.
As ye correctly pointed out its been an issue since the car was 18 months old and any repairs which have been made only last 6 month, then the original issue returns.
I've been recording the sequence of events from the start with photos, I've created a blog site to share with MB... heres the link
Mercedes Benz SClass W222 - Headlight Moisture Damage
I've even tried to contact Mercedes Sindelfingen in Germany where the sclass is manufactured but they have just referred me back to MB UK, just this week they told me to attempt one more repair with my MB dealership and if this doesnt work open a case with the Motor Ombudsman, not a road I really want to go down
Think ill try again with them hopefully they can resolve it, to be fair the dealership they haven been great to deal with. The issue lies more with Mercedes manufacturing not willing to accept there is a design flaw in the design of the headlight assembly.
Initially I had the issue in both headlights, gel packs were installed in both headlight in March 2019. Since then moisture is only appearing in the driver side so I dont believe its due to environmental issues, or washing otherwise the passenger side would be fogging also.