I'm giving this a bump as I am the OP and I have an update (problem: final beer ph too low)
I've effectively ruled out all my equipment up until the cold side.
Despite oven cooking my therminator on every batch and circulating the boil through it, I decided to no-chill a batch to rule out the chiller. The no-chill wort was 5.55 @ 25C mash, and 5.51 at pitching after 24 hours in the cube. Wort seemed sterile.
I took a sample at high krausen (48 hours) and ph was
3.98 (at gravity of 1030 when OG was 1042). What the!!!!!

This was a rehydrated US05, but I get the same result regardless of my yeast strain. Chiller ruled out. To add insult to injury I left some wort in a cup in my garage, and it started fermenting (wild yeast). After 24 hours, ph was 4.8, after 48hrs, it was 4.6. Hmm.
Does anyone know if this could be a lactic infection? There are no visual signs - the fermentation is very clean looking, and the resulting beers look perfect and clear up well. Decent head retention, kind of fresh smell, but just no malt or hop flavour, probably due to the super low PH. Doing some reading, there are things like Zymomonas which can survive in low ph conditions. But how do they get past the starsan? I just cannot understand how the ph can get this low - my mash mechanics are good. Either filtered tap diluted with RO, or 100% RO with light use of gypsum and CaCl2. Proper mash PH, etc. I have an well calibrated Milwaukee meter with 0.01 accuracy. Everything I read about lactic infections doesn't seem to reflect what I am experiencing, nor does it mention beer PH. I am not getting turbidity, sourness, or anything like that. I use starsan in my fermenters (I use glass or better bottle - no difference in result) at the correct concentration.
Next I am going to do some very small test batches with DME & RO - one in a 5L sterilised (boiled) erlenmyer, and the other in a starsan sanitised jar. I will measure the PH on each and see if I can rule out my brewing system completely. MAybe my bottle of starsan is faulty - unlikely, but one thing I have treated as a constant.
One point to add- I had a beer recently that finished at ph=4.14 (rare to get higher than 4). It was pretty good, despite the ph stil being lower than it should be (mash ph was 5.6 at 25C). But it wasnt as low as the others. This makes me think once this PH problem is sorted everything else will fall into place.
Anyway your help would be appreciated, because I need to sort this out, its driving me crazy - Well over a year of this very strange problem. I feel like my brewery is cursed.