My recommendations:
1) Individually test each modules in environment that would simulate actual usage. RMA can definitely kill you and in my case if customer need to ship (god forbids) back say v2000 unit, imagine how much is lost just to ship it back and forth. (when that happens, it DEFINITELY will cost more than value of froster itself).
2) Packing. I know you think you are doing great job with it. Yes it is better than last time. However, you still are missing one IMPORTANT thing. Antistatic wrap of some kind please! the transparent one you wrap might help protect against physical damage of good shipped, however, it will do absolutely nothing for the electrical damage it could get due to static, etc.
I don't remember getting any unpackaged (as in not in it's own plastic box, etc electronic good that didn't have antistatic bag.
3) I still have bunch of (not as much) "noise" issue. If you think it's coming from those wires... maybe trying shielded wire or twisted wire isn't bad idea at all.
4) I am not sure on this but has been hearing rumors from some. Are these controllers very heat sensitive? Considering nature of where it is used, I would think up to 60c inside chamber temperature can be expected (especially when ambient temp shoots to say 35c...)... have they been verified to work fine at those temps?
I do understand that this is 2 man show. I am not in any different situation. And my advice as usual, reduce chance of ANY RMA. 30 minute up front testing probably can save you hours if not days of work and having to eat up the cost of RMA.