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What goes wrong

It went rancid

Updated

On this page7
Nut oil oxidizes the same way any oil does, and in a nut butter it usually starts before you bought the nuts.

What it tastes like

Paint, cardboard, crayon or stale nuts. It is much easier to detect against a fresh reference than alone, which is an argument for keeping a known-good jar from each batch rather than relying on memory.

The nuts were probably already old

Nuts have a shelf life before you ever grind them, and it is shortened by warm storage at any point in a supply chain you cannot see. Grinding exposes far more surface to air and accelerates whatever was already under way. Ask for harvest or pack dates and record them against the lot.

Then storage, light and headspace

Warm storage speeds it, light speeds it, and a part-used jar with a growing air space speeds it most of all. The second half of a jar ages faster than the first, which is a reason the big format is not automatically the better deal for a customer.

Roast level interacts with this

A darker roast changes which flavors are present and can mask early oxidation that a lighter product would show plainly. That is not an advantage; it means the defect reaches the customer further along.

The fix is sourcing and turnover

Fresher nuts, bought more often in smaller quantities, ground closer to when they sell, with an honest date on the jar. None of that is clever and all of it works, and it is the same answer the oils property reaches from a different direction.

Ground product ages faster than whole nuts

Grinding exposes an enormous amount of new surface to air all at once, so a nut that would have kept for months as a whole kernel starts oxidizing in earnest the moment it goes through the mill. That is an argument for grinding to orders rather than building finished stock, which runs against the instinct to batch everything.

References

United States Food and Drug Administration. Compliance Policy Guide Sec. 570.375, Aflatoxins in Peanuts and Peanut Products, June 2021: FDA may consider peanuts and peanut products containing total aflatoxins greater than 20 parts per billion to be adulterated. fda.gov
21 CFR 164.150, Peanut butter: optional seasoning and stabilizing ingredients “do not in the aggregate exceed 10 percent of the weight of the finished food”, the fat content “shall not exceed 55 percent”, and artificial flavorings, artificial sweeteners, chemical preservatives and color additives are not suitable ingredients. law.cornell.edu
Written from federal regulation, FDA compliance policy and published food-safety research, not from a laboratory. The kill-step pages describe a real hazard and are a starting point for a conversation with your state department of agriculture and a process authority, not a determination that any roast you run is adequate.