Can you replicate that without the BM Intensity card or setup?
As a test and a workaround:
I would suggest that you export an Uncompressed "Intermediate" (avi/.mov) and encode your DVD from that.
BTW..where / how do you observe the out of synch state?
last time you suggested the same but I wouldn't know how to take the BM card out of the equation. I only have on station. If I export to Beta SP there is no problem.
If you capture a simple DV or HDV clip in a standard preset, not using anything BM, and export, do you get the same OOS error?