Originally Posted by navydevildoc

Hmmmm. Only thing I can think of is that your passport photo is significantly different than how you look now, or is old, or some other thing.

I have the same issue, My current passport photo I have no beard, but now have quite a large one. I can never get through the automated passport gates all over Europe, I always get punted to a person. In Finland the border guard says it's a common problem where the shape of your face appears to have changed. But I haven't had a problem with TSA Touchless the one time I have used it.