I would suspect dirty bottles as well. It has happened to me and I'm real anal on my sanitation. I would hold the empty bottles up to the light and see if any gunk is still in there. 22oz bomber bottles are a real PITA for me cause the bottle brush doesn't make great contact toward the transition at the neck.
I agree. OP wrote, "I wash the bottles in mild dish washing liquid and as hot water as I can stand. The about 10 min before I bottle I hit it with a dosage of star san." In my experience, what really cleans bottles is an oxygen-based cleaner such as Oxiclean or the equivalent (TJ's, Safeway, and Whole Foods carry them) dissolved in warm water, time (sometimes I soak for weeks... I love washing bottles!), a bottle brush, a strong jet-wash rinse, and an inspection of each bottle for gunk. The oxygen-based cleaner (or PBW, etc.) aggressively scrubs away junk that dishwashing liquid won't touch. I also soak bottle caps in StarSan right before bottling and make sure I sanitize the bottling tree.
I did also wonder, but this may be way off-base, if the dishwashing liquid was leaving a film that sudsed up later. But it sounds like dirty bottles.