UE4.23 highly unstable - Crashes while packing for all platforms

Hello,

I try to build an existing Project for Nintendo Switch and Xbox One. However since UE 4.23 this does no longer work.
The build progress takes forever and at some point it crashes with an error Message like below.

I tried everything, deleted all textures and materials because of the mentioning of “Error: PNG Error: invalid block type” but nothing helps. Even if I try just to ship the game with an empty map it crashes.

A entirly new project works fine. So I crated a new project and copied just the most important files to the new one and it crashes again. As soon as I use any file of the old version, it’s crashing.

Does anyone have an idea? Other wise I have a massive issue as 3 years of work are more or less worthless.

UATHelper: Packaging (Switch):   libpng error: invalid block type
UATHelper: Packaging (Switch):   LogImageWrapper: Error: PNG Error: invalid block type
UATHelper: Packaging (Switch):   LogTexture: Warning: PNG decompression of source art failed
UATHelper: Packaging (Switch):   LogTexture: Warning: Cannot retrieve source data for mip 0 of texture T_PR-9_Normal
PackagingResults: Error: invalid block type
PackagingResults: Error: PNG Error: invalid block type
PackagingResults: Warning: PNG decompression of source art failed
PackagingResults: Warning: Cannot retrieve source data for mip 0 of texture T_PR-9_Normal
UATHelper: Packaging (Switch):   LogThreadingWindows: Error: Runnable thread PoolThread 12 crashed.
UATHelper: Packaging (Switch):   LogWindows: Error: begin: stack for UAT
UATHelper: Packaging (Switch):   LogWindows: Error: === Critical error: ===
UATHelper: Packaging (Switch):   LogWindows: Error:
UATHelper: Packaging (Switch):   LogWindows: Error: Assertion failed: (Index >= 0) & (Index < ArrayNum) [File:G:\UnrealEngine-4.23.0\Engine\Source\Runtime\Core\Public\Containers/Array.h] [Line: 614]
UATHelper: Packaging (Switch):   LogWindows: Error: Array index out of bounds: 0 from an array of size 0
UATHelper: Packaging (Switch):   LogWindows: Error:
UATHelper: Packaging (Switch):   LogWindows: Error:
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffae83aa839 KERNELBASE.dll!UnknownFunction []
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa972b5847 UE4Editor-Core.dll!ReportAssert() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowsplatformcrashcontext.cpp:582]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa972b8467 UE4Editor-Core.dll!FWindowsErrorOutputDevice::Serialize() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowserroroutputdevice.cpp:79]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa9706c21a UE4Editor-Core.dll!FOutputDevice::LogfImpl() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\misc\outputdevice.cpp:71]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa970089e3 UE4Editor-Core.dll!AssertFailedImplV() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\misc\assertionmacros.cpp:101]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa97009220 UE4Editor-Core.dll!FDebug::CheckVerifyFailedImpl() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\misc\assertionmacros.cpp:445]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa95a57508 UE4Editor-Engine.dll!DispatchCheckVerify<void,<lambda_62bf5a52e83b983129b8347b2c1c1c1e> >() [g:\unrealengine-4.23.0\engine\source\runtime\core\public\misc\assertionmacros.h:165]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa952c03ba UE4Editor-Engine.dll!FTextureCacheDerivedDataWorker::DoWork() [g:\unrealengine-4.23.0\engine\source\runtime\engine\private\texturederiveddatatask.cpp:451]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa952bfeba UE4Editor-Engine.dll!FAsyncTask<FTextureCacheDerivedDataWorker>::DoWork() [g:\unrealengine-4.23.0\engine\source\runtime\core\public\async\asyncwork.h:272]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa952bfcbe UE4Editor-Engine.dll!FAsyncTask<FTextureCacheDerivedDataWorker>::DoThreadedWork() [g:\unrealengine-4.23.0\engine\source\runtime\core\public\async\asyncwork.h:296]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa96f0dbb8 UE4Editor-Core.dll!FQueuedThread::Run() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\hal\threadingbase.cpp:510]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa972b7d7f UE4Editor-Core.dll!FRunnableThreadWin::Run() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowsrunnablethread.cpp:96]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffa972abf61 UE4Editor-Core.dll!FRunnableThreadWin::GuardedRun() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowsrunnablethread.cpp:53]
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffae93d7bd4 KERNEL32.DLL!UnknownFunction []
UATHelper: Packaging (Switch):   LogWindows: Error: [Callstack] 0x00007ffaeae0ced1 ntdll.dll!UnknownFunction []
UATHelper: Packaging (Switch):   LogWindows: Error:
PackagingResults: Error: Runnable thread PoolThread 12 crashed.
UATHelper: Packaging (Switch):   LogWindows: Error: Crash in runnable thread PoolThread 12
UATHelper: Packaging (Switch):   LogWindows: Error: end: stack for UAT
PackagingResults: Error: begin: stack for UAT
PackagingResults: Error: === Critical error: ===
PackagingResults: Error: Assertion failed: (Index >= 0) & (Index < ArrayNum) [File:G:\UnrealEngine-4.23.0\Engine\Source\Runtime\Core\Public\Containers/Array.h] [Line: 614]
PackagingResults: Error: Array index out of bounds: 0 from an array of size 0
PackagingResults: Error: [Callstack] 0x00007ffae83aa839 KERNELBASE.dll!UnknownFunction []
PackagingResults: Error: [Callstack] 0x00007ffa972b5847 UE4Editor-Core.dll!ReportAssert() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowsplatformcrashcontext.cpp:582]
PackagingResults: Error: [Callstack] 0x00007ffa972b8467 UE4Editor-Core.dll!FWindowsErrorOutputDevice::Serialize() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowserroroutputdevice.cpp:79]
PackagingResults: Error: [Callstack] 0x00007ffa9706c21a UE4Editor-Core.dll!FOutputDevice::LogfImpl() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\misc\outputdevice.cpp:71]
PackagingResults: Error: [Callstack] 0x00007ffa970089e3 UE4Editor-Core.dll!AssertFailedImplV() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\misc\assertionmacros.cpp:101]
PackagingResults: Error: [Callstack] 0x00007ffa97009220 UE4Editor-Core.dll!FDebug::CheckVerifyFailedImpl() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\misc\assertionmacros.cpp:445]
PackagingResults: Error: [Callstack] 0x00007ffa95a57508 UE4Editor-Engine.dll!DispatchCheckVerify<void,<lambda_62bf5a52e83b983129b8347b2c1c1c1e> >() [g:\unrealengine-4.23.0\engine\source\runtime\core\public\misc\assertionmacros.h:165]
PackagingResults: Error: [Callstack] 0x00007ffa952c03ba UE4Editor-Engine.dll!FTextureCacheDerivedDataWorker::DoWork() [g:\unrealengine-4.23.0\engine\source\runtime\engine\private\texturederiveddatatask.cpp:451]
PackagingResults: Error: [Callstack] 0x00007ffa952bfeba UE4Editor-Engine.dll!FAsyncTask<FTextureCacheDerivedDataWorker>::DoWork() [g:\unrealengine-4.23.0\engine\source\runtime\core\public\async\asyncwork.h:272]
PackagingResults: Error: [Callstack] 0x00007ffa952bfcbe UE4Editor-Engine.dll!FAsyncTask<FTextureCacheDerivedDataWorker>::DoThreadedWork() [g:\unrealengine-4.23.0\engine\source\runtime\core\public\async\asyncwork.h:296]
PackagingResults: Error: [Callstack] 0x00007ffa96f0dbb8 UE4Editor-Core.dll!FQueuedThread::Run() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\hal\threadingbase.cpp:510]
PackagingResults: Error: [Callstack] 0x00007ffa972b7d7f UE4Editor-Core.dll!FRunnableThreadWin::Run() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowsrunnablethread.cpp:96]
PackagingResults: Error: [Callstack] 0x00007ffa972abf61 UE4Editor-Core.dll!FRunnableThreadWin::GuardedRun() [g:\unrealengine-4.23.0\engine\source\runtime\core\private\windows\windowsrunnablethread.cpp:53]
PackagingResults: Error: [Callstack] 0x00007ffae93d7bd4 KERNEL32.DLL!UnknownFunction []
PackagingResults: Error: [Callstack] 0x00007ffaeae0ced1 ntdll.dll!UnknownFunction []
PackagingResults: Error: Crash in runnable thread PoolThread 12
PackagingResults: Error: end: stack for UAT