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The issue is with reloaded brass. Start with new brass and keep close track of how many cycles it has seen. .40 S&W was the biggest offender due to the high pressures generated. Don't just scoop up the remnant cases at your gun range unless you know it's once-fired. Expect to retire your cases after maybe 3 cycles.
When I was shooting the 40 for IDPA, I'd buy 1000 empty cases of Starline Brass. It's good stuff and easy to ID when you're picking up off the range. I'd get many more cycles since I was building "Mouse-loads" to meet power factor but eventually dumped the caliber and went to a G17 for better shooting.
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