Oh how the mighty have fallen! [UPDATE]

BlendTech sent me out a replacement and made the process simple and easy.  I have been reducing the amount of frozen fruit I am putting in.  I have also upped the kale volume a little.  The most common mix is:

• approx. 3C Kale
• a layer of frozen mango
• a layer of frozen fruit mix
• approx. 12OZ of Orang Juice
• fill to cover with water

With this mix I hit the "whole juice" button and it ends up thin like juice not thick like a smoothie... and I hafta say, I kinda like that better.

No smoke so far so I'm gonna say this situation is fixed... I'll let you know if that changes.