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OK, here's a wild suggestion.
I remember that some preformatted USB thumbdrives would come with about 4 partitions created so that various operating systems could use them. I only found out because it prevents some bios's booting from the USB device. Is it possible the Apple formatting has done something to the partitioning?
The cure was to use a partitioning tool to remove all partitions then put back just one. It might be interesting to look at that drive using fdisk while it is mounted. Even if it looks OK, it might pay to wipe the partition table and start again. However, I seem to remember that Windows fdisk wasn't good enough to sort it out, and I had to use fdisk under linux. I imagine one of the better disk utilities out there on the market could also do it.
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