soon: oooh dear! That's awful! Can't imagine what it could be! As surely the fabrics are all the same, and as you say, made by same person/same pattern! That is really puzzling! I had washed it 4 times I think - in Surcare non-bio - no fabric softeners or anything nasty! Do keep me posted on it though - hopefully it's a one-off and won't happen again! Especially as you've been having such success with the other one you have.
Re: telling them apart...I'm assuming yours was made with aplix, and the one I sent you has orange velcro? Or did yours have colours touch tape too?
So far, since stopping the fleece lined nappies, I'm happy to say we've not had anymore leaks! (And he's actually sleeping much better too!!! )I wasn't sure yesterday if Benjamin was starting to get a bit of rash from feeling damp all night, but his skin seems OK today, so hopefully nothing to worry about.