I have been getting a lot of rust looking material in my new pot also. Bought 9-5-14. The new pot runs a lot hotter and it runs out when I first get it going. Good thing I run a little pot underneath . Saved my butt more than once. Been pouring for 30 years and using the same lead I used with my old pot that just burnt the element into. There is a big difference with the current model for some reason. I suspect it is temp related. It also acts like there is a reaction with the pot metal material. New problem for me also.