Let's go back to the powder. Yes, smoke sells good powder.
First question how did you apply it and how thick a coat did you put on? [pictures would help]
Did they pass the smash test (hammer the boolit into a penny or a square and NO PC should flake or chip)
What temperature did you bake at?
Did you test your oven to see if it was actually reaching 400°? (almost all countertop ovens settings are off, some over 50° low) I test my ovens (that aren't hooked to PID's) every time the surrounding temperature changes ( I had to turn one up 20+°)
How long are you baking the PC for? Manufacturers specify XX minutes AFTER the boolit reaches 400°
OR the PC starts flowing/melting. I've found that 25 min in a pre-heated convection oven that has a heat retaining material in it (I cover the bottom of my oven around the elements with ceramic BBQ briquettes others use fire brick, lava rock or? anything to hold the heat and help the oven get back to operating temperature faster)
Are you using a convection or toaster oven? Toaster ovens work but you need to bake small batches.
OK
You answered these questions "Baked at 400 degrees for 20 minutes. in a toaster oven. Confirmed stable temp with a thermometer before cooking."
It's easy to overload a toaster oven and some take a loooooong time to return to temperature. I would strongly recommend getting a convection oven! I got 2 nice convection ovens at thrift stores (1 - $15 and 1-$20)
Pictures are very helpful.
I would start by making sure the barrel was clean. Bake a small batch (25-50) in your preheated toaster oven for at least 25 min and see what happens.