You can use a formula to calculate the maximum amount of powder your barrel can burn. It is 11.5 ( grains) per square inch of barrel bore. To run the calulation, take the bore diameter, say .50, for a 50 cal. rifle, then divide that number by 2 to get the radius.
.50 divided by 2= .25
Square the radius, .25 x .25 = .0625
Now multiply that times Pi, or 3.1416
,0625 x 3.1416 = .19635.
Muliply this times 11.5 grains per cubic inch:
.19635 x 11.5 = 2.258
If your barrel is 36 inches long, multiple the length of the barrel - 36 inches - times the number above.
36 x 2.258 = 81.3 grains approx. ( 81.288).
Now, that is the maximum amount of black powder you can burn with a Patched Round Ball. But rarely is this the best or most accurate load you can use in your gun.
All this really means is that once you pass this point in the amount of the powder you put in the gun, you will begin seeing the velocity flatten out( using a chronograph ), and if you do shoot your gun over a white sheet, snow, newspaper, etc. you will find more and more unburned powder leaving the muzzle. Unburned powder contributes nothing to velocity, but it does add to the recoil of the gun.
So, just as a basic measure for your gun, run the formula and see what your maximum powder charge of BLACK POWDER is for a PRB in your barrel. You can pack in more, and maybe even burn more if you really compact the powder, using 3Fg instead of 2Fg powder, etc. If you use conicals the formula above will not give you a proper reading. It is for round ball, Only. Your most accurate load will usually be several grains of powder LESS than the maximum load your barrel will burn efficiently.
And, of course, this formula has nothing to do with any of the substitute powders now on the market. Many have much higher ignition Temperatures( that is how they get their " non-explosive " rating so that they can be shipped and stored like smokeless powder), and therefore burn at much hotter temperatures. These substitute powders are truly apples to oranges when compared to Black Powder.