[Prathamesh Sathaye] ” have played the file on VLC,MPC,Elecard Mpeg player. It plays just fine.”
[Prathamesh Sathaye] “My Client provides Inflight Entertainment solutions, so he tests the video files on his hardware device.”
Which may mean your playback devices aren’t representative of his playback device. Perhaps VLC etc. is much more forgiving.
[Prathamesh Sathaye] “I have previously delivered video content to him with the same above specs and it worked fine.”
Which means
Something changed on your end such as software update
Something changed on the client’s end such as software or firmware update
The encoded file is bad.
Since you must explore the cause to fix the problem you’re options are:
1) Re-encode the file again to see if it’s an issue with the encode.
2) Test with another file to see if the issue is specific to your source file. Give him the test file since you’re testing isn’t indicative of his experience.
Each of the above will yield results that may inform you of the next step to take.
If both the re-encode and the new test file fail it would mean something on your end or his end may have changed whether software or firmware.
3) if you believe you’ve updated software you may want to regress to using the version used to encode the last file compatible with his playback device.
This would eliminate possible change on your end. You’d have to discuss with the client possible changes on his end or, otherwise, explore other options such as testing different software.
[Prathamesh Sathaye] “Digital Rapids is the only encoder we have at the lab.”
3) You can download trials of Episode, Squeeze (or request a trial of Vantage) to see if another encoder with the same settings will yield different results.
This is all assuming that you are certain you’ve made no changes in the settings of your encoder you’ve been using to deliver to him previously.