Hi Gary,
We have stopped using cast steel shots since some years back. But looking back to the beginning of the late 80's we realized that we had the variance you're referring to. We simply added a requirement to our purchase specification as follows:

All steel shot shall be subjected to 100 cycles of peening against a hardened steel surface. Shot velocity 60 +/- 5 meters/sec. Blast angle 90 +/- 5 degrees. After cycling the shot shall be size graded, to fulfil sieve analysis requirements of AMS2431/1.

After incorporating conditioning of shots at the shot supplier we got away from that problem.

Best regards