but DMS does not sound like the off flavor you described. Also it sounds like you did what you needed to do to avoid having DMS in your brews. Your process sounds like 1,000s of other's processes and most don't have a problem with DMS.... Still sounds like a water or fermentation issue to me. Just my 2 cents.
I realize i'm inexperienced relative to a HBS owner but I do wonder about the DMS diagnosis. From everything I've read, the taste is clearly more similar to a chlorophenol description. i don't do ANYTHING that should contribute to DMS other than a slow cool-down because of the temp of Georgia tap water in the summer. An IC doesn't do a whole lot of good!
on this new partial mash IPA i left my water out overnight to run off any chlorine, meticulously soaked, rinsed and sanitized, topped off with spring water, and i've monitored ferm temps to the extreme ( checking swamp cooler temp 3X daily, average temp 58-62) People recommended using dry yeast but Wyeast came with ingredients so i pitched it. Nice active ferm going on now.
One other weird thing is that the Kolsch that I mentioned previously (my most recent extract batch) has been VERY inconsistent taste-wise. some are very good, no off-flavor but sometimes still plastic burps. others are VERY strong off-flavor, with horrible plastic burps. This I simply cannot explain. Still have a case left so we'll see. it's aged long enough in bottles that it certainly should be good by now so it's not green, i know that much.
I don't know how but I guess this could be a bottling issue.
i will sanitize bottles with starsan and spring water rather than tap water this time.