^^ or possibly stretching of the stitching at seams is more likely?
Surely if the Xply stretched at glue join between film, thered be some sort of delam visible /evident?
If you are only just tensioning battens to remove wrinkles then theres no way itll cause issues or damage sails.
How much FORCE you using????
Sounds kinda Excessive.

Maybe you should put a Loadcell on each batten?
Is there even that much adjustment to get a batten that tight on a modern sail??
And
If it had that much tension, surely itd force an S into the batten???
Sail just wouldnt Sit right or Rotate properly.