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Assuming the first two sessions were successful and used the same loads, my first thought is that the Pyrodex is contaminated. It has a reputation for degrading once the original package is opened and exposed to humidity. Pyrodex has no particular aversion to being compressed like 777 so it's very unlikely the problem is seating the ball too hard.
Regarding the caps falling off the nipples: common problem and there are no magic caps.
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