Just to confirm, what variation in COAL are you seeing? The length of these bullets can vary by at least 10 thousandths within a lot and more from lot to lot.
I've loaded up a lot of Sierra 77s over the last year, and BTO spreads within 500-ct boxes have been nothing like as large as that. I would have expected that from Sierra some years ago, but my recent experience with MKs and TMKs has been very good - ~0.003" (and I batch them to 1 thou' too on the comparator).
What does vary though is the BTO between cartons, up to 20 thou', so COAL may need adjusting on starting a new lot. Can't speak for standard 100-ct box to box variations.
What brand of brass are you using and what is the average case volume? You could possibly buy yourself a little more case volume by switching to a brand of brass with larger internal capacity/volume.
Sound advice. There is a lot of difference between makes of 223 case. If you're loading a limited capacity model, switching to a roomier one will help considerably.
Im using a Redding competition seater. 23.0 to 23.6 is where I have been playing around at. I backed down to 23.0 in hopes of reducing the seating variation. I just had the seating stem out and didn't see any cracks, but I will take it to work and have it dye checked.
I've not looked at the relevant webpages for a while, but Redding used to state that its Competition Seater dies must NOT Be used on compressed loads. I certainly screwed up a 223 Rem Comp seater in short order loading 69gn MKs onto compressed charges of Viht powders many years ago. It's the ultra close fit of the small O/D seating stem in the collar. It's so close that when part pulled out upwards, the stem will only slowly and smoothly drop under its own weight. If you load bullets onto heavily compressed loads, it comes under too much pressure and both binds and ultimately distorts. Either way, the die stops working as it should. So check the stem's fit and free movement before anything else.
From Redding's Tech Line & Tips re this die:
https://www.redding-reloading.com/t...168-working-with-your-competition-seating-die
the relevant words being:
To hold the bullet concentrically, the Bullet Alignment Bore and the Seating Stem have been honed and ground to virtually the same diameter as a jacketed bullet. As a result, the seating stem walls are relatively thin and not as inherently robust as the Seating Plug in a standard Seating Die. Though the Stem is heat treated to make it as strong as possible, it will not endure the excess seating pressure of Compressed Charges. This excess seating pressure will crack the Seating Stem which will, in turn, damage the other internal parts of the Die. Please be mindful because replacement parts are costly and NOT covered under Warranty. Please remember that your Competition Seating Die is a precision instrument and should be used and treated as such. A handloader using this Die to compress powder is tantamount to a machinist using a Micrometer as a C-Clamp.
Although, Redding says it will crack the seater stem, that's not what happened to mine, or to some other owners' dies. They either distort or bell-out marginally towards the open end in which case they also no longer fit and move properly.
Otherwise if the die is OK and you're using a roomy case, then it's back to increasing neck tension. (Even so, you might want to consider using another make if you continue to load compressed charges.