25 grains is way too much powder... so I'm not surprised there. What I meant with my question was IF proper loading data was provided, essentially converting loads to smokeless. Shotgun shells were originally black powder (hence the dram equivalence system) and most shotguns can run fine on both black and smokeless. Shotgun shell loads are restricted to max pressures pf 10,000 psi - 12,000 psi, so that means smokeless doesn't necessarily mean high pressure. As I understand it, smokeless powder develops pressure based on grain size and how compact they are. So is that it, smokeless just isn't reliable in a muzzleloader because they can't compact it uniformly with the ramrod, even if it was using the slowest-burning largest grain powder out there? But if that was true, stuff like Blackhorn 209 would blow up guns.
Your post opens up another question, why DON'T manufacturers utilize better barrel metal for their muzzleloaders? I wouldn't mind paying extra for a safer gun, but I guess Savage already provided us that with their 110... Still every other manufacturer seems content to use the same low-carbon steel or free-machining stainless for all the blackpowder guns they sell. Why not provide the option of heat treated 4140, or even just 4130? I would want that extra margin of safety, even if I was just loading straight black powder, there would still be the risk of double loads and short stops.
Seanmp: I agree with you, if I ever get into muzzleloading, I would stay with powder and not even touch the pelletized stuff out of principle. But I'm just more interested in the technical aspect of why we can't use smokeless!