I've had to open my share of reloads, too. It's usually because I was pinching pennies and tried to get just one more reload from a sad looking hull. I have several boxes of practice loads with black Xs across the bases. The X means, "Don't even think of trying to reload me again!"
In all honesty, I've never had a failure of one of my tournament reloads (fist and second reloads). But, I've had a bad factory load cost me a target and the event at a major tournament.
I think two factors for successful reloading are inspection and record keeping. I eye-ball my reloads while re-boxing, and then label the boxes with computer generated stickers. This may seem like overkill, but it works for me. I know some folks who keep their reloads in bulk: They go from the loader to buckets and then the buckets go to the range or field. These loads are never really inspected, you'd better have a good memory to know what's in which bucket.