So I did some experiments at home to try to sort this out.
First, I put the problematic gas canister in the freezer and let it sit there for a few hours. I pulled it out and connected it up to the stove. To my surprise, it actually turned on with a decent flame. I guess my freezer is above the vapor pressure of at least one of the gases. I have no thermometer to actually measure it.
Next, I put two different canisters in the freezer along with the stove, one brand new one and the one I took on my trip. I left them in there for a few hours, and then tried again. No flow whatsoever on the problematic one but the new one lit right up. So it seems that it is something to do with both the canister and the stove being cold.
Next I put the problematic one back in the freezer with the stove and tried again, with no gas flow. I then put the canister in a water bath and still no flow. I then tightened the connection a bit, and I got some flow. Then I really ratcheted it down, probably more than I should have. I got full flow. Then just to be sure, I connected it to the new canister and I got flow when it was connected in a normal way without really ratcheting it down.
So my conclusion is that when the canister gets cold, part of the valve contracts or some internal piece gets stuck. When the stove gets cold, the little pin may get a bit smaller. Then when I screw it on, the pin just can’t open up the valve on the problematic canister, but works fine on other ones. So essentially, there was probably some sort of QC issue on the canister in terms of manufacturing the valve. I suspect it just sits too low or one of the internal mechanisms just gets stiffer in the cold. This can be fixed by really ratcheting it down, which is not recommended because you can damage the threads.
Interestingly, I actually tried ratcheting it down in the field and it didn’t work. I suspect I didn’t ratchet it down hard enough. I had to torque it to the point that it pretty much wouldn’t rotate anymore.
I’m not going to test every canister this way before I go out into the field. That’s absurd. I will just bring two canisters (as I always do), but I really am surprised that this happened. It was MSR IsoPro. I wonder if this happens with other brands. I’ve used MSR, Olicamp, SnowPeak, and GSI without any problems prior. I bought a remote canister stove which can run inverted to avoid all the finnicky nonsense of getting canisters to work in the cold, but I guess it just didn’t work this time.
People swear up and down that the MSR Reactor is a snow melting machine. It’s the go to stove for the local mountaineering community. When it’s in the 20s outside, that seems to defy the laws of physics, but maybe there is some sort of witchcraft involved.