First question: if the swaddler works, why go through the whole routine of pacifier and flipping over? I agree with the other poster about the "game" of losing the paci; at this age they can't put it back in themselves, so unless you want to do this forever, it's probably time for him to either figure out how to put it back himself (can you unswaddle his arms?) or to stop using it. Second: are you sure he's not hungry? He could be having a growth spurt or something. Just because he slept through last week doesn't mean he's always going to at this age (my son slept through once at that age, once again 6 weeks later, and not consistently until 7 months).
I feel like if they can't go back to sleep for a long period, they probably have some unmet need. If not hungry, have you ruled out teething? My son sleeps worse in the second half of the night when he has mouth pain.
Third, I agree with the poster who says he needs an earlier bedtime (although 6/6:30 may be too early), try moving him towards 7:30/8.