It seems that iTunes is the problem. I think it's falsely reading copyright problems in my electronic labels. So the answer is to load the iPod without using iTunes.
By googling I know this is possible. There are numerous hacks and third party software that claim to do this. I sent one of these programs to my customer but it's way beyond her abilities. I've taken a look and see that, yes, these are for tech-heads only.
I have hundreds of customers using my program in iPods. But if this problem is due to a new feature it's going to keep happening.
Does anyone know of a SIMPLE way to bypass iTunes when loading an iPod? I don't use one so I don't have a clue.
Another angle may be for me to change my electronic labels for the mp3 tracks, but I have no idea where the issue is.
The only option left is to refund the customer, which is a real shame as she bought the mp3 player specifically to use with my program!
Thanks for any suggestions!