I have to say, I find this thread troubling for a specific reason.
I purchased last years model Float 30 bag early this season. BCA let me test a bag at the snow show, and I was very impressed with the bag, and the ability to refill the can without returning it to the manufacturer. Upon receiving my bag, I filled the can (It came empty) and did a test deployment. The effort required to blow the bag was the same as I recalled at the show, and very simple. No major effort at all. Filling the can is only $3.00 at my local shop, who asked for a demo, so I deployed it in the shop as well. Worked flawlessly, as expected. I've since also blown it at a Search & Rescue training. Works exactly as expected in my experience.
My buddy (Snowest member) also obtained two Float 30's at the same show. One unit last years model, the other, the most current model. (Different outer material, waterproof zips, different shape pull handle, are the primary differences that I can tell.) He called to ask how hard he had to pull as he could not get either bag to deploy when his arrived. After confirming he put it together correctly, (You cannot assemble it incorrectly) I drove to his house to check them out, and tease him for being a wimp. In his case, both bottles came filled, so I don't know which is normal as mine came empty. I can without any doubt say that you could pull until your arm broke, neither bag would deploy. We took them back apart, and reassembled, even rotating bottles between the two bags. Same outcome. No amount of effort would make them work. Since both his bottles were full, we could not take apart the trigger mechanism in the bottle to inspect it. Both bottles were returned for inspection.
As I have had my bottle filled 3 times, I've assisted in filling mine, and know how the trigger mechanism works. Other than the possibility of rotating the trigger to the wrong side of the bottle, when disassembling it to refill, there is no way it can be put together "wrong". I was, and remain, impressed with the design of the unit.
Knowing two new bags out of the box don't work, concerned me enough to blow mine again when I got home. Worked perfectly.
Reading this post, some are speculating it could be the temp of the bag, ice buildup, ect. causing the problem. The two brand new units in question I attempted to deploy were at room temp so at least with these, the problem isn't temp. related. I thought about posting about our experience as soon as I got home from my buddies house, but held off. After reading this post however, I had to put out what I have personally experienced. I have read the reply about updates to the pull handle, pull strength required, ect, but I am very interested to see what the problem is attributed to on my buddies bags as the issue with my buddies units appear to both be in the trigger within the can itself.
It's also important to note, as a long term BCA customer I purchased what they produced because they have created great, reliable products which have served me well. Having full confidence in gear that potentially could save my life, or the life of those I ride with is priceless. I am, and will remain a solid BCA customer of many of the products they build. I cannot stress enough that MY bag has worked every time I have tested it, although I will be testing it now more than ever. Which can't be a bad thing by any reasoning.
Hoping our experience is unique.