Thanks for all the responses. Really appreciated.
This morning went over the shoes again and made sure they were dead clean, stoned them very slightly incase there were any knicks, backed the pressure off a bit on the trimming station and the chipping on the first side cut went away immediately, second side got worse. Took Rob's advice and throttled the fall of the second trim slightly and for now the first batch of parts are fine.
Kirk, That was my very first thought when this happened, that the router had developed a knick or was leaving a tiny flash on the bottom side but even flipping the parts it would still happen but still watching it closely. Im trying to address 1-2 issues at a time hoping to find the true cause.
Daniel, I need to look at that a bit next, Im going to put a thick piece of MDF in the bander and make sure those shoes are hitting square to the panel (as square as I can get them).
Stuart, I will hopefully see if the shimming is necessary with the thick part test and checking the shoe alignment. Like I say, its trimming fine, its just the shoe on both trims was chipping out the material where it contacted the edge of the part.
At this point Im honestly feeling like it is some percentage of commodity material, and the trimming station pressure.
Its back to banding just fine at the moment but that can of course go awry in a nanosecond.
Thanks again guys for all the input. Major major help.