Don,
Thanks so much for the help. After many more late nights tinkering it seems the problem to be mostly procedural, switching between PP, AE, Speedgrade, then Encore. We were overlooking something that was recompressing our footage (x2). So, the BR players weren’t able to handle the mega compression.
Still trying to find a way to get DoStudio on a win 7 setup (we have Win 8). DoStudio says the Win 8 compatability will arrive summer 2014.
Perhaps the universe gave finally us the “a-ha” moment after we posted the question. Same thing happens at the mechanic when I take my car into the shop, the problem has miraculously disappeared.
Thank you