I am sorry, I just do not understand what your problem is.
As I have outlined above, I have shot in most every conceivable weather condition, from high humidity to dry as a bone, from stifling high temperatures to well below zero and from the east coast to the west coast. I have shot with factory guns to custom guns, and with Patent breeches to flat breeches. I never have had ignition problems. And I am talking percussion guns here, not flinters.
So, what is the secret to this success? I don't think it is using .22 caliber brushes to clean the breech. I don't think it is using funny little scrapers to clean the breech. I don't think it is any of those ideas, because I have never felt the need to use them. In my life, I have probably shot in excess of my body weight in black powder, and that would be 1,575,000 grains of the stuff. I think the secret is that I never clean the rifle by just running a wet patch up and down in the barrel. It seems to me that would just push fouling into the breech. I always flush the barrel and ignition chamber with Ol' Thunder Bore Solvent by removing the barrel from the stock and immerse the breech into a soup can full of the solvent and flush the barrel by running a patched cleaning jag up and down in the barrel. I use three patches, typically. One to clean the barrel, another to dry it out and a third to lubricate the barrel with Just Good Lube. Fast, easy and economical. From initial teardown to final re-assembly, it is faster than a person can smoke a cigarette.
Then when it is time to shoot again, I simply run a dry patch down the barrel to wipe out any oil lingering there and pop a cap or two to make sure the ignition passage is clear. Presto, we are shooting again. Nothing to it.
I will confess that I have had hangfires on occasion in the past. But I attribute that to the fact I was testing some big bore rifles with Pyrodex powder.
And the situation cleared up as soon as I switched back to black powder.
But, all this is just my experience. I cannot speak to what you are doing or the results you are getting.
(Joe, I have never heard of popping a cap to clear the chamber prior to loading each shot. Seems excessive to me.)
John (Bigsmoke)