When I got active in local PPC matches, the Star Reloader was the most poplular progressive press out there although their were others that were quite useful. Police departments often had a designated reloader for the department. During a PPC match, it was not uncommon, with lots of people shooting on the line to hear the normal "pop, pop, pop" then a BANG! You absolutely KNEW that "Bang!" was a double charge. The common 2.7 grs. of Bullseye with wadcutters was used a LOT! The quick reload required on some stages were a round nosed bullet with another light load of powder. A double charge would not blow up a K-frame revolver but did get your attention. However, enough new shooters with NO reloading experience got into the game. They, of course, HAD to have a progressive loader. Put a progressive loader in the hands of CLUELESS shooters, and suddenly guns began blowing up. The NRA commisioned H.P. White to try to find out what was causing the blow ups. They DID find out (a double charge PLUS deep seating of the bullets) raised the pressures to somewhere north of 60,000 psi and destroyed revolvers, right and left.
The lessons learned were remembered when IPSC got popular. However, IPSC shooting also had their share of blow ups but not nearly so much as the PPC problems, as I remember.
The same thing happened AGAIN, when SASS became popular. New shooter/reloaders with NO CLUE about proper reloading procedures. The interesting thing was that, by that time no one seemed to remember the NRA reporting on PPC. So, all of the speculation began all over again. Progressive presses were blamed for the problems instead of the real cause - the operators.
Full confession:
I have had one SUSPECTED double charge in my .32 H&R Mag Smith Model 631. I was rabbit hunting with a friend (shotguns), and the friend shot a rabbit (around the edges). The rabbit came near me and sat down. I pulled my 631, and put a S&W Long topped with a 98 gr. RCBS SWC through the slats, settling the issue. However, I knew by the report and increase in recoil that I had loaded a double charge. Since the original load was reasonable, and in the "magnum revolver", no damage was done. However, I took it to heart and rigged up a better light so I could see down in the case when loading. I also made certain that I "looked" at each loaded case just after the powder dropped.
I also re-examined my loading procedures and realized that the most dangerous time is when starting up the press after an interruption (biggest problem was failure to drop a charge at this point). Distraction was limited and followed. In other words a "new protocol" was developed the minimize the dangers.
During my IPSC years, occasionally my two young sons, who also were taught to run the Dillon, would discover a round without powder (once or twice). That was corrected. Neither I, nor my sons, lost a single point during the five years we shot IPSC and ran matches. I probably shot in fifteen or twenty matches a year. Counting practice, I shot 75,000 rounds in five year period of .45 ACP alone (full charges). My two sons, together probably shot about half as much.
A couple of years ago, my youngest son was visiting, and we, together decided to load some .38 Specials for he and his wife. Remember me mentioning distraction, well, when starting up the press after a break, I, while loading and talking to my son, failed to put in a charge in a case.
So, progressive presses are NOT the problem, but "lack of experience", distraction and/or improper "protocol" CAN be a problem. That is correctible.
The worst "accident" that I have had in 69 years of shooting, bullet casting, and reloading, was with Military factory 30'06 in a O3A3. The ammo had been given to me by a friend who neglected to tell me he had had serious problems with the ammo. I believe it was the third shot fired. The case split from the primer hole to the outside of the case dumping the whole charge through the action. Particles of brass blasted my face and would have absolutely blinded me had I not been wearing safety glasses. It looked like I had been shot in the face. It drew blood but I was able to pick the brass from my face (with help) and did not require hospitalization. So, everything is relative.
P.S. This FACTORY ammo was very old (but looked to be in very good condition) corrosive ammo. After my problem (and another friend had been gifted some of this ammo with the same results) we did a little research. We learned that that ancient ammo had a bad past. Either of us could have lost our vision. I did have a talk with the original gifter and we still remain friends to this day. I chalked up his failing to youthful ignorance.
Keep safe, friends!
Dale53
FWIW
Dale53