I've never had an issue with Starline brass so this surprises me.
It happens.
...And isn't as uncommon as one might think.
I've had major issues with Starline .44 Mag, .458 SOCOM, .32 H&R, and .32 S&W Long.
Most issues involve excessive neck tension, or zero neck tension, from no annealing process after final forming; combined with stupid-small neck diameters (such as .447 for .458 SOCOM, with up to 0.025" thick neck walls) or stupid-big neck diameters (like 0.318" for .32 H&R and .32 S&W Long).
Second to that, I'd say primer pockets and/or flash holes improperly formed.
I've also had minor issues with all of the above, plus .480 Ruger and .444 Marlin.
Even Starline screws up.
And, sometimes, they do it on purpose.
In 2003, Tony Rumore (Tromix) had a production run of .458 SOCOM brass come in with the shoulder so far back on the cases that they split when fired (one of his reasons for offering case gauges now...
).
As Tony tells the story, he contacted Starline and they were so arrogant as to tell him there's no way they could have shipped out-of-spec brass, because 'all of their products are perfect'.
The next time they ran .458 SOCOM for him, he made sure to request proper case dimensions. They sized so that the shoulder was 0.040" too far forward and the necks too long, so that he could fix it himself.
Quality.
From Starline's
own website:
Another unique step in Starline's manufacturing process is our close quality control and hand inspection between each step. Our quality control personnel inspect each case for cosmetic defects and sample cases dimensionally with micrometers and precision gauges to ensure the tightest tolerances possible.
Every case is run through our final inspection machines to guarantee 100% flash hole presence, correct length and diameter. Our tight quality control system means every caliber is inspected a minimum of ten times during the manufacturing process! Sure, multiple inspections and holding tight tolerances increase production costs, but Starline will never waiver in our commitment to quality.
That being said...
Last year, I was given a sample of pre-production .444 Marlin brass.
I fired and resized one piece 62 times with a full power load, before I gave up on trying to make it fail. It was work-hardened like a son of a boondoggle, but didn't fail before the shooter's arm was jello.