Load development is very over blown. I doubt the different bullet length caused the issue. Probably either a different issue with the bullet (maybe diameter small, or cores are shit with voids, etc) or an issue with gun or optic.
I would guess the problem is something wrong with gun (i.e. mechanical or something loose), a problem with the optic or mounts, or the new lot of bullets is shit. I have never seen a good gun shoot bad with Lapua brass, a good powder, and Berger bullets. I can literally pick a speed and shoot. As long as it is not over pressure a 223 is going to shoot that brass and bullet with say 4895, varget, or xbr into 3/8" to 1/2" at 100 yards for 5 shots. Pretty much all reasonable charge weights and a jump that is .040" or larger will do that. Also, just touching the lands seems to shoot damn good in everything as well.
It is rare for load development to take a 2 moa load and make it a 1/2 moa load unless the 2 moa load is over pressure or very low pressure (case not sealing chamber right away). I will say, I had a coyote/whitetail gun I wanted to shoot Hornady 105 bthp out of. Same gunsmith as usual, known good powder, bartlein blank, Peterson brass. After a bunch of fucking around I had a 3/4 moa gun at 450 yards, and I was pissed. I called the gunsmith and asked what I was doing wrong. He said stop shooting hornady. I'm a stubborn ass, so I sorted all the Hornady bullets by oal into lots of .002". Like magic I turned it into a .5 moa gun at 450 yards for 5 shots. I shot 6 5 shot groups to confirm. Largest was right at 2.375" with some running under 2".
There is a reason benchrest shooters like to use custom bullets. I would check scope rail, rings, and scope for problems, check the bore with a borescope, check for bedding issues, and test again. If they are still shooting like that I would be making a call to Hornady.
When I want cheap bullets I have found that sorting the hornady bthp match bullets by oal will usually shoot well. When I want to shoot sub 1/2 moa for 10 shot groups, you guessed it, berger or custom bullets.
I will give sierra a little credit and say that I have ok luck with them, but not as good as Berger. Hornady has been very hit and miss.