Hi
@burgoyne , are they modded consoles? or original ones?
Well, you can try to reformat, use the files of the FW-Kernel that is installed now, and copy just a little amount of games to the microSD to test. *IMPORTANT* Every file that you copy to the microSD card, make sure that if it is compressed, NEVER copy it from the ZIP-RAR-7ZIP file, always extract it first to your PC, and then to the microSD, it can lead to issues with files.
Also, create a folder with the name "SAVER" in the root of the microSD card. Make sure you are using batteries that are in a good shape.
If you get it working at least once, install the FW&Kernel from the comment #405, make sure that you never press any button during the installation. And after it is over, turn off the console, and then on.
If your consoles are not modded it's very weird to have this issue with that amount of consoles. Are you sure that your microSD cards are from a reliable seller (AKA Original)? Because I don't know in the US, but here Sandisk-Kingston there are a lot of copies of this brands if you don't know where you're buying.