What kind of supplements are you adding to the gutload?
There is some speculation that some vitamins/minerals in excess may lead to increased mortality by interfering with the molting process. The influences of extra calcium ions or some other (unknown) nutrient might influence the hormone cascade necessary for ecdysis and development into subsequent life stages... this is only speculation though. The fact that you are having them "split" suggests there may be something going on that is preventing proper molting or throwing off the time when molting should take place.
I've not personally had an issue with it, but have also heard that substrate that is ground too fine can block the spiracles ('breathing holes') and cause the insects to essentially suffocate. I'm not sure I buy this one, because I think mealworms can handle pretty fine substrate without any issue, and by the picture your gutload looks like it would be just fine. An old friend, Ronnie Buck, informed me of this. He used to operate cricketfood.com and made some of most nutritious cricket and mealworm gutload around, so I still feel this is worth mentioning as I see him as a reliable source.