I'm confused at your point Wyatt. If you are doing a classic pass, you aren't conceiving a new pass, right? You are doing a classic pass, and although noise can be covered, doesn't justify its existence. The pass is supposed to be silent because it's a secret action. Many of the actions that cover it, the jiggle, riffle, spread and so forth are not meant to cover the noise but the motions of the pass, they are meant to justify the actions. Understandably, that doesn't mean your pass has to be 100% silent, but it's something you should definitely be striving for. And i think magicianlist is also right, in most cases you shouldn't be using the pass for every single card control or every routine, it's practicality is not as widespread as it was once thought.
As for the original poster, you have to give the packets a bit more space to clear than you might think. Try extending your pinky more with the top packet when performing the move, this will help with the bottom packet scraping against the face of the top one, and should help the side of the original top from scraping against the face of the original bottom. Hope that helps.