the envelope sender is mandrillapp.com, and the only thing that changed when we changed our server is our dkim and spf became valid
We don't send from our own servers, so the envelope is different to the from - really no serious mail service should take any serious notice of that, especially considering the valid dkim and spf!
Just as a curiousity, I sent a subscribe email to one of these mail tester sites:
http://www.mail-tester.com/web-pGR4dX
It only really tells you it's not blacklisted, dkim+spf are valid and it scores well on a standard spam assassin rule set - but all sorts of spam rules are configured on all sort of servers, gateways, anti-virus and even mail clients! I've personally always found google and outlook do a good job of stopping nearly all spam with very rare false positives.