If this is something that is being converted to something more valuable (like in my example above of Titanium Coating recipes to Titanium Coating IOs to Aegis/Unbreakable Guard IOs), then it could be for a lot of reasons. It could be a sloppy mistake. It could be fat fingers (I had a doozy yesterday). But even when I was running TCr -> TCio -> A/UGio, although I was buying the TCios as well as the recipes, I never really sweated it if one way was significantly more profitable. They both were profitable! If you could eke out a few more shekels by selling directly the intermediate items like the TCio, so be it, but I have found that focusing on the process is a lot faster. Of course, it also makes sense to refine the process as time goes by and consumer habits change.
As to your last point, that sounds about in the ball park for my really working a market segment. Back in the heyday last summer, TCr -> TCio -> A/UGio was netting me about 500mm a day, iirc.