Excellent points! I don't have any rat-eating snakes any more, & I sure don't miss thawing rats, especially those larger than "small"- their fur is very thick, so it "insulates" their body, making it much harder to THAW them. If you don't really feel them deeply with your fingers, it's easy to miss it if they aren't fully thawed internally...I wonder if that could be the OP's problem here? Combined with how fast they cool off, if, as you suggested [Luvyna], only the quick heat from a blow-dryer was relied upon too heavily to get the job done.
I also agree that I'd try feeding smaller rats- male BPs seem to accept them more reliably. Plus they're easier to warm. It just doesn't pay to try to make up for missed meals by giving meals that are bigger than the snake wants anyway.