It adds another step in the loading process, but he could try a card-wad over the powder charge, followed by the patched ball.
You don't state what powder he's using,... sometimes a mere change in powder can be enough to prevent the shredding of patches.
Also,.... those Uberti Santa Fe's had a rather sharp crown, so using either Emory-cloth, or sandpaper and his thumb, he might take the sharp edge off if the patches are being cut when he "starts" his ball.