Well I can certainly see a few areas of where I was going wrong and heartfelt thanks to the all who have suggested where matters might be improved. The question of aperture had never occurred to me as in my innocence I was thinking that the smaller the aperture the better the DOF without even realising that this created another set of problems with a digital sensor.
Diffraction softness due to too small an aperture opening affects film - it's not limited to digital sensors.
Digital sensors do make evaluation of sharpness against a known standard ("crisp at 100% pixel magnification") easier. Thereby it is easier to find that you have an issue with diffraction.
If you shot a 4x5 at f/64 and compared it side by side with a strong loupe to (or large print of) the same image at f/22 you'd find the same softening of fine detail.
There are many image-quality issues that digital makes easier to find. In my opinion there are two equally important lessons to take from that:
1) To be technically perfect on a medium requires greater skill/effort/control as you increase the quality of the medium.
2) The aesthetic, business, emotional, practical value of an image do not necessarily depend on technical perfection. Part of film's gift was that there was less "pixel-peeping" (or in this case "high-magnification loupe analysis").
Don't get be wrong on #2; I work as a technician at a high-end camera dealer because I understand and
appreciate the nuance (and minutia) of the technical side of imaging. There are several genres where technical perfection is often a prerequisite to the image's efficacy: grand landscape, architecture, product/still-life, medical/scientific, art-reproduction,
cultural heritage imaging, film scanning, aerial and many more. In such genres the raw capture nearly always needs to be sharp, well exposed, and properly color managed ("proper" might include a non-neutral WB). It goes without saying that these technical merits are only the pre-requisite; the image must
also be visually compelling, tell a story etc.
In other genres the image itself does not
necessarily need to exhibit any technical perfection to be an effective image ("effective" could mean visually appealing, monetarily successful, making it's creator personally proud or anything else). But even in these genres having a good understanding of the technical "rules" of photography make it easier to control/guide the creation of the image, and to break the rules with purpose rather than depending entirely on happy accidents.