Are you using the same spray on multiple vehicles?
The terminal spray is not actually conductive, even though that seems counter intuitive. That is how it prevents the corrosion though.
"CRC Battery Terminal Protector (05103)
CRC’s 05103 spray forms a durable, non-conductive film that prevents acid corrosion and oxidation. Its red dye makes application easy, ensuring full coverage. Ideal for harsh climates, it
extends battery life and improves conductivity."
I read this on the back of a can and got a good chuckle about how the non-conductive film improves conductivity.
It could be a number of things, impurity in the battery posts(basically all major brand battery have recycled content now) or on the cable end connectors, a change in formulation of the spray, or some other connection issue elswhere. Hard to say.
I used Duralube spray lube for years and years, but they stopped making it. It came out purple, and was like a synthetic spray grease, but more fluid and slightly tacky after it "dried". One of those oil soaked cloth washers on regular post type batteries also helped prevent corrosion by putting a barrier in between the battery gasses and the connection. Not possible to use those on modern side post/screw in types.
I am not really a fan of the purpose made terminal sprays. They don't seem to hold up to WI weather as well and require maint. intervals to reapply, but I have not found a similar product to the old duralube yet.
I have never used it on things before connecting, I just hose things down after everything is tight to seal it up. It won't be as effective that way but I have never had an issue and never had the connections get bad before the battery went bad, even in the old days when you might have an old Megatron last 15 years.
The first result in my amazon search, but there are cheaper versions of the washers: