We know haki "blooms" in the heat of battle. Similarly, Devil Fruit awakening most likely unlocks while engaged in top level combat. Hence, why the Gorosei ordered the interference.
I dunno if you're trolling, but where is Sanji for real? This isn't completely out of the question. We've seen Sanji carry out stealth operations before. Against Enel and at Enies Lobby, etc...
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