OK so a couple notes...
I found the setting to slide up the preload memory size... I'm not 100% if it's doing the job... Funny thing is on one song it seemed to be working (I'll know better once I go play it in my car... the crackle is much more apparent out there than on my monitors/headphones... but it does seem to be working). But on the next song I tried, it didn't seem to be making a difference...
SO, I went to the other suggestion of creating a new project and copying that single midi track over to it with a new instance of Omnisphere using the same patch. Now it did seem to save the higher preload memory size as a default in omnisphere, so we're working with that and a brand new sonar project... And comparing the two is night and day, it's totally clean in the new project, then I jump over and its crackly (even when soloed) in the other project.
SO, I tried another thing... I froze the track in the original project and it freezes with the crackling... No good... BUT then I froze the track in the new project and copied the frozen audio over, and that works great.
SO... We've got a serviceable, although annoying workaround. But, what is it exactly that's going on here? Is it a resources issue? I would have thought freezing the track in the original project would be good enough for resource related issues. According to the Sonar resources thing I'm using 57% of my system memory.
Also I tend to use just one patch/channel per Omnisphere instance. The song in question uses 9 instances, along with a bunch of other VSTs.
For now, I think that one track that I just fixed using the new project and freezing and copying the audio over method was the only track crackling in this particular project, so I'm gonna go finish it up. But if anyone has any further thoughts on this, I'd definitely appreciate it. I'm hoping that maybe with the upped pre-load memory size, it'll at least be better for new projects going forward?
Thanks again for your help. Sorry, I know this is a long post haha.