So everything mentioned here so far has been tried to no avail. Just chocking it up to "whatever can go, will go wrong" on this one. Ricoh production facility said they had no issues whatsoever but threw the samples away rather than sending them back to us to see so we just moved forward with die cutting the job just to get it out. I can only guess at this point in time that possibly our knife sharpening company isn't getting it quite as sharp as needed but we have never had this issue before sooooooooooooo ..... thanks everybody for your ideas and I will post a resolution if we ever figure one out
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