Losing variable. Element is undefined in VARIABLES - coldfusion

Question

We are getting this error in both ColdFusion 9 and ColdFusion 11 servers in production. I originally thought is related to ColdFusion 9 and JavaHeap space or not enough memory. We moved this process to run on a brand new server (ColdFusion 11) where nothing else is running and has a lot of memory and we still get the error. Here is some of the code for this cfm page:
<cfset variables.email_count = 0>
<!--- email notifications --->
<cfoutput query="getOrdersForNotification" group="order_id">
<cfset variables.inv = "">
<cfset variables.usePdf = false>
<cfif isDefined("application.feature_list_using_pdf_attachment")
and listFindNoCase(application.feature_list_using_pdf_attachment, "injection scheduler", ",")
>
<cfset variables.usePdf = true>
</cfif>
<cfthread name="InjectionSchdEmail#dateFormat(now(), 'mmdd')#_#timeFormat(now(), 'HHmmss')#_#getOrdersForNotification.order_id#"
threadOrderId="#getOrdersForNotification.order_id#"
threadMemberId="#getOrdersForNotification.member_id#"
threadNotificationEmail="#getOrdersForNotification.notification_email#"
threadDateReq="#getOrdersForNotification.date_req#"
threadStoreCode="#getOrdersForNotification.store_code#"
threadStoreName="#getOrdersForNotification.store_name#"
threadToGoLabel="#application.togo_label#"
threadOrderTotal="#getOrdersForNotification.order_total#"
threadDelTimeValueFront="#getOrdersForNotification.del_time_value_front#"
threadSubject="#variables.subjectAndBodyTemplates.subject#"
threadBody="#variables.subjectAndBodyTemplates.body#"
threadFromEmail="#variables.fromEmail#"
threadLocalNow="#variables.localNow#"
threadLocalNowInt="#variables.localNowInt#"
threadDs="#ds#"
threadUsePdf="#variables.usePdf#"
>
<cftry>
<cfset url.order_id = threadOrderId>
<cfset url.member_id = threadMemberId>
<cfsavecontent variable="variables.inv">
<cfinclude template="invoicedeska.cfm">
</cfsavecontent>
<cfset variables.order_day=dateFormat(application.UdfService.toSlashDate(threadDateReq), 'mmm dd')>
<cfset local.subject = threadSubject>
<cfset local.subject = ReplaceNoCase(local.subject, "[Store Code]", threadStoreCode, "all")>
<cfset local.subject = ReplaceNoCase(local.subject, "[Takeout Label]", threadToGoLabel, "all")>
<cfset local.subject = ReplaceNoCase(local.subject, "[Order ID]", threadOrderId, "all")>
<cfset local.subject = ReplaceNoCase(local.subject, "[Order Total]", NumberFormat(threadOrderTotal,"9,999.99"), "all")>
<cfset local.subject = ReplaceNoCase(local.subject, "[Required Time]", threadDelTimeValueFront, "all")>
<cfset local.subject = ReplaceNoCase(local.subject, "[Required Date]", variables.order_day, "all")>
<cfset local.body = threadBody>
<cfset local.body = ReplaceNoCase(local.body, "[Store Code]", threadStoreCode, "all")>
<cfset local.body = ReplaceNoCase(local.body, "[Store Name]", threadStoreName, "all")>
<cfset local.body = ReplaceNoCase(local.body, "[Order ID]", threadOrderId, "all")>
<cfset local.body = ReplaceNoCase(local.body, "[Order Total]", NumberFormat(threadOrderTotal,"9,999.99"), "all")>
<cfset local.body = ReplaceNoCase(local.body, "[Required Time]", threadDelTimeValueFront, "all")>
<cfset local.body = ReplaceNoCase(local.body, "[Required Date]", variables.order_day, "all")>
<cfset local.body = "<span style='font-family: Verdana, Arial, Helvetica, sans-serif; font-size: 10px; color: ##000000'>#application.UdfService.multiLiner(local.body)#</span>">
<cfif threadUsePdf>
<!--- PDF version --->
<cfdocument
format="PDF"
name="variables.attachment"
localURL="#application.pdf_localURL#"
orientation="#application.pdf_orientation#"
marginleft="#application.pdf_marginleft#"
marginright="#application.pdf_marginright#"
margintop="#application.pdf_margintop#"
marginbottom="#application.pdf_marginbottom#"
unit="#application.pdf_unit#"
scale="#application.pdf_scale#"
>
#variables.inv#
</cfdocument>
<cfelse>
<!--- HTML version --->
<cfset variables.attachment = variables.inv>
</cfif>
<cfmail to="#threadNotificationEmail#" from="#threadFromEmail#" subject="#local.subject#" type="html">
#local.body#
<cfif isDefined("variables.attachment") and threadUsePdf eq false>
<cfmailparam
file="invoice_#threadOrderId#_#threadLocalNowInt#.html"
type="application/html"
content="#variables.attachment#"
/>
<cfelseif isDefined("variables.attachment") and threadUsePdf>
<cfmailparam
file="invoice_#threadOrderId#_#threadLocalNowInt#.pdf"
type="application/pdf"
content="#variables.attachment#"
/>
</cfif>
</cfmail>
<cfset invoice_emailed = application.MessageService.setEmailedInvoice(orderId = threadOrderId, localNow = threadLocalNow, emailAddress = threadNotificationEmail, datasource = threadDs)>
<cfcatch type="any">
<cfset variables.attachment = "">
<cfmail from="erroralerts#monkeymediasoftware.com" to="erroralerts#monkeymediasoftware.com" type="html" subject="POS injection notification email faliure">
<cfif isDefined("cgi.server_name")>
Server: <b>#cgi.server_name#</b>
</cfif>
<cfdump var="#cfcatch#" label="cfcatch"><br />
<cfdump var="#threadOrderId#" label="threadOrderId"><br />
<cfdump var="#threadMemberId#" label="threadMemberId"><br />
<cfdump var="#threadNotificationEmail#" label="threadNotificationEmail"><br />
<cfdump var="#threadDateReq#" label="threadDateReq"><br />
<cfdump var="#threadStoreCode#" label="threadStoreCode"><br />
<cfdump var="#threadStoreName#" label="threadStoreName"><br />
<cfdump var="#threadToGoLabel#" label="threadToGoLabel"><br />
<cfdump var="#threadOrderTotal#" label="threadOrderTotal"><br />
<cfdump var="#threadDelTimeValueFront#" label="threadDelTimeValueFront"><br />
<cfdump var="#local.subject#" label="local.subject"><br />
<cfdump var="#local.body#" label="local.body"><br />
<cfdump var="#threadFromEmail#" label="threadFromEmail"><br />
<cfdump var="#threadLocalNow#" label="threadLocalNow"><br />
<cfdump var="#threadLocalNowInt#" label="threadLocalNowInt"><br />
<cfdump var="#threadDs#" label="threadDs"><br />
<cfdump var="#threadUsePdf#" label="threadUsePdf"><br />
<cfdump var="#variables.inv#" label="variables.inv"><br />
</cfmail>
<cfrethrow />
</cfcatch>
</cftry>
</cfthread>
<cfset variables.email_count = variables.email_count + 1>
</cfoutput>
<p></p><cfoutput>#variables.email_count# emails sent # #local_now()#</cfoutput>
Error:
Element EMAIL_COUNT is undefined in VARIABLES.
The error occurred on line