That workflow\workaround is exactly what tech support indicated a couple pages back in this thread.

"... Although the limit for the song length in Band-in-a-Box is 255, generally speaking the closer you get to that point the more work the Band-in-a-Box engine taxes your computer and thus can create some pretty unwanted results.

As a general rule, the shorter the song the better it is. Even if you need to export smaller portions as a .wav then import them into another DAW to increase the length of it that would be a good work around.

No matter how much we may want BIAB to behave differently, it generally comes down to the fact that there is a workaround to get done what you need. It is just a shame sometimes that so much effort goes into learning this lesson for newbees. But as long as you are having fun... crazy
Dan, BIAB2022, SoundCloud If my response appears inappropriate - it is likely just my poor attempt at humor. If you don't like my response, just ignore it!