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The most common causes for this are:
Adhesive residue on the sprocket pins.
The sliding sprocket and bail needs cleaning and lubrication.
The foil drive clutches are slipping creating excessive drag of the foil on the vinyl when printing.
Sounds like you need to setup your Custom Spot Color Mapping for the Gerber spot color foils you plan to use. Check you Flexi Help files for instructions.
I had this happen once and I took the glasses back to the ophthalmologist who checked them and determined that they were not what he prescribed. It was never determined whether the optician made a mistake or he was handed someone else's prescription.
I tried bifocals once and almost fell down...
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