diff --git a/.github/workflows/bb_builder.yaml b/.github/workflows/bb_builder.yaml
index c34feea..65916a3 100644
--- a/.github/workflows/bb_builder.yaml
+++ b/.github/workflows/bb_builder.yaml
@@ -45,7 +45,7 @@ jobs:
         env:
           tool_ver: ${{ matrix.manifest }}
         id: humannversplit
-        run: TMP=${tool_ver##*,} && echo "HUMANNVERSION=${TMP##*--}" >> $GITHUB_OUTPUT
+        run: TMP=${tool_ver##*,} && AFTER_DASH=${TMP#*--} && echo "HUMANNVERSION=${AFTER_DASH%%_*}" >> $GITHUB_OUTPUT
       - name: Get metaphlan version
         env:
           tool_ver: ${{ matrix.manifest }}
diff --git a/biobakery-profiler/Dockerfile b/biobakery-profiler/Dockerfile
index 2d6c946..a971e16 100644
--- a/biobakery-profiler/Dockerfile
+++ b/biobakery-profiler/Dockerfile
@@ -24,16 +24,19 @@ FROM python:3.9.17-slim-bookworm AS pybuild
 ARG HUMANNVERSION=0.0.0
 ARG METAPHLANVERSION=0.0.0
 
+# IMPORTANT: libglpk-dev is needed here at compile time
+# so that the Python GLPK bindings compile correctly
 RUN apt-get update && \
     DEBIAN_FRONTEND="noninteractive" apt-get install --no-install-recommends -y \
         build-essential \
-        wget \
-        ca-certificates \
+        git \
         patch \
         libjpeg-dev \
         zlib1g-dev \
         libbz2-dev \
-        liblzma-dev && \
+        liblzma-dev \
+        libglpk-dev \
+        glpk-utils && \
     rm -rf /var/lib/apt/lists/*
 
 RUN python3 -m venv /opt/venv
@@ -42,21 +45,53 @@ ENV PATH="/opt/venv/bin:$PATH"
 COPY nucleotide_${HUMANNVERSION}.patch /tmp/nucleotide.patch
 COPY config_${HUMANNVERSION}.patch /tmp/config.patch
 
-RUN pip install --no-cache-dir numpy cython && \
-    pip install --no-cache-dir boto3 cloudpickle awscli && \
-    pip install --no-cache-dir biom-format && \
-    wget -qO- https://github.com/biobakery/humann/archive/refs/tags/${HUMANNVERSION}.tar.gz \
-        | tar xz -C /tmp && \
-    mv /tmp/humann-* /tmp/humann && \
+# IMPORTANT: Installation order matters!
+# 1. numpy and cython MUST be installed before biom-format
+# 2. biom-format must be installed before humann
+# 3. GLPK libs must be present when installing packages that link against them
+# see: https://forum.biobakery.org/t/silent-errors-with-bad-install-of-libglpk/4814
+
+# Step 1: numpy and cython first — biom-format needs these at build time
+RUN pip install --no-cache-dir numpy cython
+
+# Step 2: biom-format — needs numpy already installed to compile
+RUN pip install --no-cache-dir biom-format && \
+    python3 -c "from biom import load_table; print('biom-format OK')"
+
+# Step 3: Other Python dependencies
+RUN pip install --no-cache-dir boto3 cloudpickle awscli
+
+# Step 4: humann — needs biom-format already working
+RUN set -e && \
+    git clone --depth=1 --branch ${HUMANNVERSION} https://github.com/biobakery/humann.git /tmp/humann && \
     cd /tmp/humann && \
     patch humann/search/nucleotide.py < /tmp/nucleotide.patch && \
     patch humann/config.py < /tmp/config.patch && \
-    mv setup.py tmp.py && \
-    sed 's|2\.2\.3|2\.5\.1|g' tmp.py > tmp2.py && \
-    sed 's|bowtie2_folder="bowtie2-2\.5\.1|bowtie2_folder="bowtie2-2\.5\.1-linux-x86_64|g' tmp2.py > setup.py && \
+    cp setup.py setup.py.orig && \
+    sed -i 's|2\.2\.3|2\.5\.1|g' setup.py && \
+    sed -i 's|bowtie2_folder="bowtie2-2\.5\.1|bowtie2_folder="bowtie2-2\.5\.1-linux-x86_64|g' setup.py && \
+    diff setup.py.orig setup.py || true && \
     pip install --no-cache-dir . --no-binary :all: && \
-    pip install --no-cache-dir metaphlan==${METAPHLANVERSION} && \
-    find /opt/venv -type d -name "__pycache__" -exec rm -rf {} + 2>/dev/null; \
+    ldconfig /usr/local/lib && \
+    glpsol --version
+
+# Step 5: metaphlan after humann
+RUN pip install --no-cache-dir metaphlan==${METAPHLANVERSION}
+
+# Verify the full dependency chain works
+RUN set -e && \
+    echo "=== Verifying dependency chain ===" && \
+    python3 -c "import numpy; print(f'numpy {numpy.__version__} OK')" && \
+    python3 -c "from biom import load_table; print('biom-format OK')" && \
+    python3 -c "import humann; print('humann OK')" && \
+    python3 -c "import metaphlan; print('metaphlan OK')" && \
+    which humann && \
+    humann --version && \
+    ls /opt/venv/bin/humann* && \
+    echo "=== All pybuild checks passed ==="
+
+# Clean up
+RUN find /opt/venv -type d -name "__pycache__" -exec rm -rf {} + 2>/dev/null; \
     find /opt/venv -type d -name "tests" -exec rm -rf {} + 2>/dev/null; \
     find /opt/venv -type d -name "test" -exec rm -rf {} + 2>/dev/null; \
     find /opt/venv -name "*.pyc" -delete 2>/dev/null; \
@@ -68,17 +103,12 @@ RUN pip install --no-cache-dir numpy cython && \
 # ============================================================
 FROM python:3.9.17-slim-bookworm AS runtime-image
 
-ARG HUMANNVERSION=0.0.0
-ARG METAPHLANVERSION=0.0.0
-
-# Copy samtools binary and its needed libs
 COPY --from=dbbuild /usr/local/bin/samtools /usr/local/bin/samtools
-
-# Copy the entire pre-built venv
 COPY --from=pybuild /opt/venv /opt/venv
 ENV PATH="/opt/venv/bin:$PATH"
 
-# Install ONLY runtime dependencies — no build-essential, no git
+# IMPORTANT: Runtime versions of the same libraries that were used at compile time
+# libglpk40 + glpk-utils must be here or humann/biom will fail at runtime
 RUN apt-get update && \
     DEBIAN_FRONTEND="noninteractive" apt-get install --no-install-recommends -y \
         libjpeg62-turbo \
@@ -92,10 +122,44 @@ RUN apt-get update && \
         libglpk40 \
         glpk-utils && \
     rm -rf /var/lib/apt/lists/* && \
-    ldconfig /usr/local/lib && \
-    glpsol --version
+    ldconfig /usr/local/lib
 
 ENV LC_ALL=en_US.UTF-8
 ENV LANG=en_US.UTF-8
-
 WORKDIR /tmp
+
+# Thorough smoke tests — verify the full chain works at runtime
+RUN set -e && \
+    echo "=== Runtime smoke tests ===" && \
+    echo "--- Binary checks ---" && \
+    glpsol --version && \
+    samtools --version | head -1 && \
+    echo "--- Python import chain (order matters) ---" && \
+    python3 -c "import numpy; print(f'numpy {numpy.__version__} OK')" && \
+    python3 -c "from biom import load_table; print('biom-format OK')" && \
+    python3 -c "import humann; print('humann OK')" && \
+    python3 -c "import metaphlan; print('metaphlan OK')" && \
+    echo "--- HUMAnN tool checks ---" && \
+    humann --version && \
+    humann_config --print && \
+    humann_regroup_table --help > /dev/null && \
+    humann_renorm_table --help > /dev/null && \
+    humann_join_tables --help > /dev/null && \
+    echo "--- MetaPhlAn check ---" && \
+    metaphlan --version && \
+    echo "=== All runtime smoke tests passed ==="
+
+RUN apt-get update && \
+    DEBIAN_FRONTEND="noninteractive" apt-get install --no-install-recommends -y \
+        libjpeg62-turbo zlib1g libbz2-1.0 liblzma5 \
+        libglpk40 glpk-utils libgomp1 \
+        ncbi-blast+ mafft raxml \
+        procps \
+        locales && \
+    rm -rf /var/lib/apt/lists/* && \
+    ldconfig /usr/local/lib && \
+    sed -i '/en_US.UTF-8/s/^# //g' /etc/locale.gen && \
+    locale-gen en_US.UTF-8
+
+ENV LC_ALL=en_US.UTF-8
+ENV LANG=en_US.UTF-8
diff --git a/biobakery_build_manifest.csv b/biobakery_build_manifest.csv
index bab1bb7..8bc8841 100644
--- a/biobakery_build_manifest.csv
+++ b/biobakery_build_manifest.csv
@@ -1,3 +1,3 @@
-biobakery-profiler,4.0.6--4.0.0.alpha.1-final-smaller
+biobakery-profiler,4.0.6--4.0.0.alpha.1-final_smaller-pt2
 biobakery-profiler,4.1.0--v3.9
-biobakery-profiler,4.0.5--3.6.1
+biobakery-profiler,4.0.5--3.6.1_smaller-pt2