Do you use lots of irish moss? I find when using irish moss this happens, more so when i use extra. It usually never drops out & the beers taste fine. Sometimes it's extra chunky looking. I don't use anything other than irish moss so i'm curious if whirlfloc would be different.
set I: Pale (3) -> Mild (4-5) -> amber / Victory (20-25) -> special roast (40-50) -> brown (70)
set II: pilsner (2) -> Vienna (3-4) -> Munich (8-10) -> dark Munich (20) -> aromatic / melanoiden (25-30)
encore: smoked (5)