It seems most likely that this is an issue happening with the GPU MMAL drivers. One thing we have learned is that they do not deal well with errors and generally cannot recover when one occurs. What capture software are you using? Are the systems identical (including size/make of SD memory card)? Many things can cause interruptions that create errors, but they can be difficult to track down. As one example, the flash memory file system can “pause” when large amounts of data are being stored. We have not found a reliable way to reinitialize the MMAL drivers after an error.