I attach below an example of an initial contact e-mail reply to a commercial company for an economically competitive sized SAA production facility. This gives a hint of what is involved. The facility is scaleable and customers may require extra capacity in certain areas so treat this as a General Introduction, thank you.
GMT-DEMIL is here to help as PROJECT MANAGERS & CONSULTANTS.
SMALL ARMS AMMUNITION PRODUCTION FACILITY.
We can supply you a full range of the latest designs of NEW machinery and equipment to complete your project. Ammunition projects usually include the following:-
For an annual production to rival the large commercial names in the US industry to make your own cases and bullets in five various calibres and then assemble these components ready for sale to the market . . . .
We are looking at an initial investment for a basic commercial operation in excess of
6.5 million USD.(price includes our commission)
1) Brass Cartridge Case Production: 1a > 1l
The traditional processes involved are as follows. However we have large single modern machines that combine many of the processes including 1a) to 1i)
1a. Punch Press for sheet metal copper alloy cups
1b. Machine for cartridge case drawing from produced cups
1c. Machine for cartridge case trimming
1d. Machine for case indenting and heading
1e. Machine for firing holes piercing
1f. Horizontal press for necking
1g. Machine for visual inspection of cartridge case
1h. Machine for grooving and cutting
1i. Machine for dimensional inspection of cartridge case
1j. Machine for induction annealing of cartridge case mouth
1k. Machine for visual inspection and varnishing of case
1l. Machine for priming and varnishing
2) Bullet Manufacturing: 2a > 2g
2a. Lead wire extrusion press for lead bars to lead wire
2b. Machine for lead core manufacturing
2c. Machine for jacket cups & bullet assembling
2d. Machine for bullet grooving (cannerling)
2e. Machine for bullet size control
2f. Machine for bullet weight control
2g. Polishing drum
3) Complete Cartridge Assembly Line from components: 3a > 3b
3a. Machine for cartridge assembling
3b. Machine for visual inspection of cartridge
4) Packaging Equipment
5) Ballistics Equipment (Quality & Safety Testing)
We are looking to offer machinery to minimize labour but keep high quality standards and a controlled environment. We offer machines for commercial application only. Machines can be tooled in various calibres but there is a big change of machine design from handgun size ammunition to rifle size ammunition production and then another jump to 50cal and small cannon.
You are looking at three main areas of expenditure.
1) New Automatic Case making from metal strip is initially expensive to setup, but the machines should last you at least twenty years at full capacity with only tool replacements required as they wear and go out of tolerance.
2) New Automatic FMJ Bullet making - again expensive to setup initially but should last fifteen years at full capacity with justtooling expenses.Combining c) to e) in one machine.
3) Assembly of components can be done on a budget if required using multiple readily available machines of dedicated calibre setups.
Installation of quality control systems and Ballistic testing and packaging requirements to all international standards is
straightforward and available off the shelf. So if you want to make your own cases and bullets only - then you
will need a minimum project budget of at least 4.5 million USD. It will take at least 9 months from order to make the NEW machines and a further 3 months to ship, install and commission.
Financially all these machines will require a contract agreement with you detailing prepayment deposit and stage payments at the time of ordering as they are specially made to serve only your specific requirements. At all stages of the contract your personnel are involved with periodic practical inspections and monitoring of the machine manufacture process. We would allocate a small experienced GMT-DEMIL team to manage all aspects of our involvement in the project and close liaison with yourselves is essential to its success.
If you are able to be flexible USED older designed machinery would require a good practical engineering team at your facility, as these machines will give trouble eventually.
We can offer our own personnel for training and engineering support and consultancy on a contract basis at very reasonable prices. We can help design your facility to maximize safety, production efficiency and security. We can also supply experts on other external threats if required.
European made equipment is available to the USA via our company here in the UK without many restrictions and we have connections with most manufacturers to help serve your needs. We can always act as your liaison in direct negotiation with manufacturers, if required.
So at this early enquiry stage, let us know how you want to proceed and the capacity and money available.
Should you ask us to produce a Rough Order of Magnitude (ROM). We plan the offer by first - using the amount of finished loaded product required to be manufactured by the customer and then work backwards to cost the machinery and equipment for the necessary components.
Some of the fastest loading machines are rated at producing 10 - 12,000 completed cartridges per hour. (In practice this becomes about 9,000 per hr per machine averaged over an 8 hr working shift. A daily maximum of two shifts with maintenance split shift of 4 hrs after 8 hrs work.) [Standard machines have a loading rate of 6000 per hour which in practice averages about 4000 per hr production.] Even with new fully 'automatic' machines it is not a case of feeding components, press the go and stand back. They need to be monitored at all times and adjustments may be necessary or your quality goes down.
In the ammunition trade you are only as good as your last batch. You will need a quality control laboratory continuously sampling & measuring the ballistics of the finished product and a practical firing range for functioning tests.
For a standard facility we would recommend you start with ten loading machines initially and work up to those larger capacities with extra production cell purchases as operation of these machines require some skill and training. It will give time to train your personnel. It will also give flexibility to establish your market sales leaders and link to dedicated calibre production lines. To make money you need to plan to run your machines for as long as you can per day. All personnel will require induction training to bring everyone up to a safety standard.
A standard industrial building is fine for making the inert components like cases and bullets. Loading the cartridges is usually done in a specially designed building and site with surrounding open land for storage of explosive propellant and finished items. You will need an explosive storage magazine, dedicated loading and unloading facilities etc. These safety distances are important for your investment in the facility and people. Safety distances are linked to quantity of explosive stored and its effect in an accident, a comprehensive risk assessment for the site and building design will be needed. The loading machines will need specially designed loading halls and auto powder loft feeds which are not usually suitable in a general purpose industrial building surrounded by neighbours. The local & state authorities may also have some imput for conditions of your licence due to the large quantities of explosive powders and finished product stored and worked, this needs an early check out. Your local climate & security may also have some imput on the building designs needed. If you propose to manufacture in the future for the Government then a Quality Management System (QMS) for all aspects of the business is essential which we can install for you.
Any contract with us is split into self contained sections. Payments in general would require a deposit and then stage payments at the completion of each stage or section of the contract.
Our planning services can be provided separately as required. We have in the past provided just the planning and machine & equipment requirement lists, facility and training, if this is what fits into your plans.
Stage payments would be similar to:
1) Deposit at Order placement, percentage depends on section-stage.
2) Machinery & equipment manufacture
3) Inspection & machinery shipping
5) Operational commissioning
6) Personnel Training
7) Ongoing consultancy for up to 5 years, as required.
We are quite happy to sign a non disclosure agreement if you ask us to work for you and we will fly over to see you to get things going. If you contract us we will use local people whenever possible to complete the project. The more information you can give us at this time allows us to improve the draft structure of the financial offer to you.
Initially, planning work can be prepared here in UK after a visit to your proposed site.
You will already know your proposed capacity from the business plan from your financial department. It will then be used by us to dictate the quantities of machinery and equipment required.
For an operation of the above standard size type, a single industrial building like a 40,000sq ft space would be fine but safety spacing will have to be internal and you really need to separate your explosive stores from your stock. In an ideal designed facility for safety and security we encourage many smaller buildings spread throughout the site but this depends on your circumstances.For the military application - earth shelter & underground bunker production buildings are a particular interest of GMT-DEMIL.
The latest thoughts on linking production with refurbishment, recycling and demilitarization needs can be incorporated into the facility design with particular attention to environmental and future proofing.
I am sure you are aware but to refresh:
In general an ammunition factory is normally split into the following work areas:
1) Office. (administration)
2) Inert component part production. (cases, bullets & any other ammunition components, packaging material)
3) Inert raw material store and finished part stores.
4) Hazard 4 Explosive items assembly (Assembly halls for your finished product)
5) Hazard 4 Explosive Stores (for propellant, primers and finished product)
Also separate goods loading in and out for explosive items or inert.
For safety reasons these areas need to be separate. Areas 4 & 5 need to be separated by a good amount depending on the quantity of explosive involved. This separation can be achieved by internal blast/ fire walls or other forms of segregation in certain cases.
For the above size of investment you will need to get it right from the start or you could have practical operational and unacceptable safety risk problems.
As you can see, we need to know the proposed size of operation. We are totally adaptable from one machine to several factories. The supply is scaleable in most cases - so don't panic. We are here to help you achieve a successful project.
We will wait for your primarily capacity figures to allow us to produce a rough order of magnitude (ROM) price budget for your project.
There is no charge for preparation of the project ROM. Then if you want to employ us as Project Managers we will come over to see you and take it further.
Bob LAWSON - GMT-DEMIL - Operations Director
T. +44 (0)1935 823 201
F. +44 (0)1935 826 208
Contact us for more details of your specific requirements, thank you.