I think the zipper pulls are added at the end of putting the zipper on the gear. Sounds like a major quality control issue.
When I bought my ENO I left it sitting for a long time, when I went to use it the biner was crummy. I called ENO, they were very helpful, they sent me two new biners right away. I was impressed with the service and attitude.
Hennessy sure was not nice to deal with, my 2 month old tarp has the finish separating from the nylon, I am not impressed. I am not even going to contact them about the issue, since they were nasty when I called about the Snake Skins I purchased direct from them, had a hole in the seam, I noticed the hole when I opend the package they arrived in.
ENO was really excellent, I would have bought the biner from them, very nice to deal with.