I’ve had this happen to my Barley Crusher. You mentioned it was with the hopper full and maybe you were tight on time. I’ve had success opening the gap slightly and then running the grain a second time on a tighter setting.
It was workable and got me through a brew day. Afterwards, I would disassemble, clean and relubricate the rollers (which seems to buy me a couple of years before I need to clean it again). I’ve had mine for about 15 years and I’ve had the clean it 3 times (I think).
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