I would do a bunch of measuring and try to narrow things down like that. You have to measure things to know things in reloading, the rest is guessing.
The very first and most simple thing I would do would be to make sure that the length of a sized case is within spec for your chamber. It would seem like the first place to start and don't recall seeing it suggested. If the brass has flowed and the case needs trimming it can pinch the projectile and not release it. This can happen from the very first reload. This seems to me like the most likely reason. You can just trim to spec and test fire, or measure your chamber length with a little insert sold by Sinclair and others that fits into a case to measure where your neck length stops. You could just trim to the length of the virgin and check.
Do you size the virgin brass before loading, or seat straight into the case neck? Your neck tension with the sized brass may be excessive. Again you can measure to check.
Another thing would be to make sure that a bullet drops into a fired case - i.e. no doughnut and most likely not a too tight neck. It would seem strange that the neck dimensions would change aside from forming a doughnut. Measure the outside neck diameter of the ammo loaded with virgin brass and your reloads in fired brass. That should tell you if something changed. Also whilst shooting the 1x fired brass shoot some virgin brass loads at the same time - this should help tell you if you have a carbon build up causing you issues, as that should be a problem with both.
Test firing would be a good idea with loads at lower levels it seems.
You may have mentioned it and I may have missed it, but I assume all of the other components remained the same, same bullets, same seating depth, same primers and powder lot number etc. If not you have introduced a bunch of other variables to check out.
Check out one thing at a time.