Got it. Thanks. I also have a phone call into Mahlkonig to see what they say. They might echo what you said about the multiple lbs being used as a break in period because this is a commercial grinder. I just want to rule out any equipment malfunction. Interesting...when I called Mahlkonig USA they only had one tech that could answer my problem and he was out of town. Wow.
Each grinder I've owned has provoked a similar reaction in me. It takes a bit of time for a) the machine to break in and b) for you to learn its' inherent idiosyncrasies. After a few months I now know that if I wear the goat leggings while I dance under a waxing moon while the tide is rising I will get a very consistent time-based grind from my Mazzer. Wearing street clothes it's more of a crapshoot and I always seem to toss about 1/2 to 1g that I've over-ground each day. By toss I mean that I toss it into a bag marked "guest coffee" for when my Folgers-drinking in-laws visit, so it's not even really wasted.
From my personal experience (which, I freely admit, is limited at best) I have found that the larger commercial grinders were never designed for single dosing... they all retain a few to many grams of coffee in the grind path, they are equipped with dosers instead of grounds bins, and one must WORK to come up with ways to get around these limitations. What they offer in return is simply superior grind quality, and THAT is what you paid $1,600 for. Hands down, the Baratza grinders have the most consumer-friendly features and lowest grounds retension... that's why people like them so much. I hear they are coming out with a true commercial machine which, although probably substantially more robust than the Vario series, will likely not even approach the simplicity and ease of use of the Vario-W's weight-based dosing.
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