After distributing Zakat al-Fitr this year, a large portion remained undistributed due to time constraints before the Eid prayer. Fearing sin, we distributed it to those who had previously received from it, and to those not eligible. Was this correct, or would it have been better to distribute it to its truly deserving recipients after the Eid prayer?

All praise is due to Allah, and peace and blessings be upon the Messenger of Allah, and upon his family and companions. To proceed:

You erred by giving Zakat al-Fitr to those who are not entitled to it. Charity should be distributed early, and the Companions used to give it out one or two days before Eid. If you are unable to distribute it before the Eid prayer, it is permissible to delay it, and the majority opinion is that the entire day of Eid is a time for distribution. As for what you paid to those who are not entitled, you are accountable for it and must give it out again to the deserving poor. And what you paid to the deserving poor in excess of their needs is sufficient, as it is permissible to give more than one fitra to a single poor person, just as it is permissible to distribute fitra among more than one needy person.