Before we can give you a reasonable answer, you need to retreve some of the patches and tell us what they look like.
New barrels often have sharp edges on the rifleing grooves and these can cut the patches.
Some of the new BP replica powders burn hotter than real BP and can burn thru the patch.
The patch lube can make a big difference in protecting the patch from this burn thru, so that is an important bit of information too.
If the patches are pre lubed, and are quite old (like they have hung on the desplay rack for years) they may be ready to fall apart from the breakdown of the material.
You didn't say what powder load, patch thickness and ball size you used. Any one of these can ruin a group if they are not correct for your barrel.
IMO, if the barrel is not cutting the patch, and you are useing a good ball patch size combination (like .530 ball and .015-.018 thick patch) with a good patch lube (like WonderLube or spit), and a reasonable powder load like 65-75 grains, you should be getting a fairly good group.
zonie