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At wits end with this persistent problem - anybody have any insight?

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I wouldn't store anything with star san on it. Not a corrosion issue, but it leaves a film. Best to store items clean and dry. I never do get all the water out of my plate chiller, but I make sure to boil it before use. I also do that with my airstone. Nooks and crannies that you can't see....
 
My funny tasting brews were due to my plate chiller. I stopped using it and my brews were back to tasting normal. I did everything you were supposed to do to clean, sanitize this plate chiller. Nothing worked. I tossed it out.
 
Tossed it? !!!!! Boiling should have taken care of any contaminants. Hot PBW should have got out any chunks, so theoretically a starsan dip would be fine after the PBW, but I still boil. Tip most of the hot water out and then use a baking mitt to drop it in starsan till I need it later in the day.
 
I did all that. Oven baking, PBW, star san, you name it. Whatever got in it, I couldn't get it out. As soon as I used my old immersion chiller, good beer.
 
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