gert,
as usual you come up with an interesting problem, and in this case not a pleasant one.
not having an answer, some things that come to mind.
would it be worth comparing 1f, 2f, and 3f powders of best quality?
would it be worth trying a kicker of 4f, as in duplex, but with all black?
faster powder in the small case might work better, but might also make the problem worse.
could a felt wad soaked in grease replace the overpowder wad with a wax paper under it for any benefit?
if you are running an airgap, could some wad fill that space to prevent the issue?
i have tried a 1/8" felt wad in the airgap of 40 and 45 cal breech seated loads, and it works well, both greased and ungreased, but your round will probably have a smaller airgap.
straight felt will compress a little, while greased felt will not.
keep safe,
bruce.