I've used blended materials for near 25 years (450+, 452X, BCY-X) and never had that happen. Probably just got a bad spool. Haven't kept up with how many BCY-X strings I've made, but I started using it 7 or 8 years ago (when it came out) and I'm sure I've made over 1,000 strings with it. It's my favorite material.
I don't think it matters how it comes off the spool, but I let the spool spin between my fingers or if it gets warm I'll grab a screwdriver and let the spool spin on that.
If the material kinked up from just being on a bow, definitely a bad spool. With the amount of material BCY runs every day, it's going to happen...but it's rare. I've used hundreds of pounds of BCY materials over the last 20+years I've been using BCY...as best I can recall, I've run across maybe two 1/4# spools that weren't right--they were replaced, no problem.