The Massachusetts Fire code does not require the plastic bag
http://members.tripod.com/New_England_Brigade/Artilleryinfo/527022.doc527 CMR: BOARD OF FIRE PREVENTION REGULATIONS 8/25/95
527 CMR 22.00: CANNON OR MORTAR FIRING...
22.06: Magazines and Powder...(5) All charges shall be made up of commercially manufactured black powder only, and such charges prepared for the demonstration firing shall be made of completely combustible material or a non combustible material such as foil. The completely combustible charge shall be encased in aluminum foil or other spark proof material which shall be removed at the muzzle of the cannon in the case of display firing. No wadding of any kind is permitted in blank firing.
It would seem that if the gimlet pulled plastic up the vent that it would be felt coming out. Then when the fuse was inserted it would encounter the blockage and not go in. It would also seem that it would take a substantial amount of plastic to block the vent or surround the fuse and "snuff it out". Not to say it isn't possible.
I know that I first encountered the plastic bag in foil cartridge method of in the Summer of 1984. I know that because I still have the copy of Summer 1984 "The Muzzleloading Artilleryman" that introduced me to the technique. Properly constructed there is little or no "slack" to get pulled up the vent. I have never encountered the problem nor have I ever heard any reports of the problem. That of course doesn't mean that the problem hasn't occurred.
What I have heard of is foil and plastic debris up the vent from firing, but that is cleared during the cleaning step of loading.
The purpose of the plastic bag is to contain the powder and keep it from getting into the folds of the foil cartridge and holding a spark after firing.
That being said as noted above above Massachusetts does not require the plastic bag and neither does N-SSA. N-SSA requires only the foil cartridge
I do like the idea of the paper inner bag to contain the powder. My concern with the plastic bag has been more that melted plastic debris would adhere to the bore than be blown up the vent. Use of the paper bag would eliminate both worries.
The safety rules of the American Artillery Association give proper loading sequences and techniques and tell how to deal with misfires. The rules specify wait periods between loading, firing and correcting misfires. The rules should be strictly adhered to.