My experience has been that this happens when the leech of the sail is too loose when furling and this allows a large fold of sail to get wrapped around the furler in the mast. We started with the full vertical battens and now have a new sail with short vertical battens. There was a learning curve for both sails but once figured out we seldom have any trouble at all. Some careful working of the sail in and out with both the furling line and the out haul has always worked for us. To keep the leech tight when furling the boom needs to be as horizontal as possible. ie topping lift loose and vang tight. On our 38 I had to move the vang position on the boom to allow the boom to lie closer to the arch, ours was set up from new with the vang such that it was impossible to tighten the leech. When furling the main you want to be into the wind, lock off the sheet, cinch the vang down, have a turn of the outhaul around the winch, open the outhaul jammer, open the out jammer for the continuous line. Then haul in on the furling line while keeping a little tension on the outhaul. It is the position of the boom end which determines how much tension is on the leech when furling. Just like when sailing a little difference in vang makes a bit difference in leech tension and sail shape. Hope that helps?