Why is the top needle assembly punching huge holes in my k cups?

Check the top needle using this guide to see if it is damaged or bent out of place: Keurig Mini B-31 Top Needle Replacement

"Top of K-Cup With Large Hole -

The huge hole in the top of the k-cup can be the result of the top of the unit (holding the penetration needle) not aligned properly with the bottom (holding the k-cup) as the needle penetrates the k-cup foil. It does not always happen, but I figured out when does happen. The telltale sign of this misalignment is when the top seems to hang-up more than usual and clicks or 'pops' a bit just as you are closing the top down and the needle is penetrating the foil. Essentially the needle enters the top foil slightly to the rear of where it shoul, then when closing the top down all the way, the needle is then pushed back toward the proper center position, creating a large hole. I resolved the problem by putting slight pressure inward on the lower k-cup housing as you are lowering the top down. The root cause appears poor mechanical design allowing misalignment of the top and bottom housings while closing."