I've just had this problem occur to me in the past month. Two weeks without riding plus med treatment and the burn returned today before I even got my leg over the saddle. I too use Chamois Butt'r on every ride, regardless of the time/distance. I am swapping tubes of Chamois Butt'r from the one I've used the last several rides to a tube of Chamois Butt'r purchased from a different source (hopefully a different batch). In addition, my next ride (three days from now) I'll be wearing shorts with a different chamois than those I've recently worn when I have experienced the problem. Our team has new kits each year so it's easy for me to pull out from my closet a totally different pair of short with a different pad. I'll let you know how it goes........