Error Occurred While Exporting 4.0.8

I've been having an issue ever since upgrading to 4.0.  I export to 256GB Kingston flash drives for performances (we do not bring laptop to the event - just flash) and we have 6 CDJ 2000's - hadn't had many issues until now.  I went out and purchased a new laptop just to help solve these issue since my old machine was a few years old, so I got a PC with the Corei7 processor to see if these were computer issues.  But - still same problems.

When I put the flash drive in, I see at the bottom of Rekordbox "exporting" and this starts at 0% and takes literally 20 minutes to "export" to 6% (and I'm not exactly sure what this export is doing??) then I get the "An Error Occurred While Exporting".  Then, I try to hit SYNC and after 3-4 minutes I get the "An Error Occurred While Exporting" error.  There does appear to be tracks exported to the flash, but I'm fearful that using this flash drive now will lead to issues on the job.  

I've been using Rekordbox since the product first became available, so I'm familiar with the processes.  My drives are all FAT32 and have had no issues until I started using the 4.0 software.

Any ideas???