So I think I just had an epiphany...Tell me if I am on the right track.
I have been brewing these newer batches of the beer in a Brew Bucket from SSTech. It is a 7 gallon fermentor. I put 6 gallons in and leave 1 gallon of head space. On every brew, I have had a decent amount of beer and yeast come out of the blow off tube into the sanitizer bucket. Is it possible that once the yeast gets blown out, that then I have too little yeast in there to keep fermenting and it is stressing them out causing the ester flavors? When I rack to the bottling bucket, there still seems to be plenty of yeast in the trub, but maybe I am loosing a large amount in the blow off.
Should I drop down to a 5.5 or 5 gallon batch in the 7 gallon fermentor and leave more head space so I am not sending yeast out of the blow off? Right now I am using a 1/2 blow off tube. Would going to a 1" reduce what actually comes out of the blow off, or would the same amount of beer and yeast get expelled through there as well.