I’m going to go with the poor powder ignition votes. Your round ball started out of the case before sufficient ignition of the powder had occurred. When the pressure dropped, ignition was slowed so quickly a goodly amount of powder remained unburned. That’s my story and I’m sticking to it.
Remedies would start with a heavy crimp on the ball, or a heavier projectile, or more powder located down near the flash hole. I hesitate to mention any kind of filler or wad as that can bring on its own set of problems, but you may need to go there.
Froggie