Arria-ii-gx excessive power consumption

Hello,

We have a design in an EP2AGX65CU17. It does decimating FIR, FFT, magnitude conversion, averaging, and then continuous DMA over PCI-e using the hardcore. We built 5 prototypes in summer 2010. These worked fine and were delivered. The power consumption was as expected from the powerplay estimates done during design. We recently built 30 production units, and are experiencing a wide variance in power consumption, with many parts running as much as 4X the power of our prototypes. Thus far, Altera support has been of little help. Has anyone seen this type of power issue with Arria-ii-gx? Thanks in advance.