Quad tone Rip from 5x7, 35 and 120negs, usually . The 35mm giving me the biggest issues.
OK, so you're inkjet printing the negs. In that case original format or digital capture don't play a role, so we can ignore that part of the process.
I'd start by printing a step wedge with your pre-determined linearization curve to verify you're getting the same result as when you had just linearized your process. Preferably using an inkjet step tablet that you used originally as the verification of your linearization procedure. If not, you have a process control issue.
Assuming you have properly linearized your negatives. If not, you're evidently shooting a moving target, but I can't imagine anyone working that way.
btw, looks like you've got coating issues here:
Are you sure your process in control?