I imagine if you contact Hornady directly they will make it right by you. I've heard nothing but glowing compliments about their customer service and commitment to the industry.
While I haven't checked boxes in the store, from any manufacturer, I've checked each box as I've opened it and started preparing my magazines. A few shotgun rounds here and there from Sellier & Bellot had some variation in construction, and a couple of Federal defensive rounds had case lips that weren't tightly sealed against the bullets. But other than these, and the rare individual round here and there that didn't feed due to apparent age-related crud on the outside of the case impeding feeding, I can't recall any overall quality issues with any of the basic brands I've consistently used. About the only "perfect" rounds I have used have come from DoubleTap, for both 9mm defensive ammo an .243 rifle ammo.