Ammo Assembly Line

High-Capacity Primer Inserting Machine

The ammo assembly line begins with the primer inserting machine. It is a high-capacity rotary-type machine based on a cam mechanism. Therefore, it is reliable and easy to maintain. It has several quality check functions to ensure a precise primer insertion. Furthermore, the quality functions inserted in this machine ensure that the shell cases are good enough to continue with assembly.

The system is designed ex-proof and further safety precautions are taken. The primer feeder is placed in a safety enclosure and the machine does not operate until the feeder is safely enclosed. Primers are slid down from the feeder to the machine through a tube, creating a safety gap in the tube. Furthermore, a sound detection system is embedded in case a primer ignited to shut the system down. Click here for further information about the Primer Inserting Machine.

High-capacity Sealing/Varnishing Machine

The primed cases are transferred to the sealing machine from the primer inserting machine via elevator conveyors automatically. In this setup, the sealing comes before loading. Considering the risk of gunpowder or primer contamination by moisture, gun oils, etc. especially in military ammunition the machine ensures cartridge mouth circularity first, then sprays an asphaltic sealant/lacquer around the primer and inside the cartridge case neck at the same time for a strong-enough attachment of the bullet. Finished products are buffered on a linear slide to allow the sealant to cure.

The asphaltic sealant machine is a rotary-type machine based on a cam mechanism. Therefore, it is reliable and easy to maintain. Its continuous motion provides high-capacity throughput.

Based on the end user’s preferences the asphaltic sealing machine can be replaced with a UV-curing sealing machine where the sealant is applied on the primer and the case mouth after the loading of the cartridges. Click here for further information about the Sealing Machine.

High-Capacity Ammo Loading Machine

The primed shell cases (also varnished if an asphaltic sealant is used) are transferred into the loading machine automatically. This high-capacity rotary-type loading machine can produce multiple calibers including pistol and rifle calibers. It also has a cam mechanism. Therefore, it is reliable and easy to maintain. Its continuous motion provides high-capacity throughput. The loading machine is embedded with several quality control functions to ensure that the gunpowder level, length, weight, and loadability/full form of the cartridge are accurate.

The loading station is the point where the bullets and the gunpowder are fed to the system. The loading machine is built ex-proof and all the safety precautions are taken to safely handle the gunpowder. Bullets are fed to the system through the bunker and the elevator conveyor feeds the machine’s feeder with bullets automatically. Click here for further information about the Ammo Loading Machine.

Quality Assurance

During the assembly, all the imperfections on cartridge components that would lead to a misfiring are eliminated. By the time cartridges exit the loading machine their quality control is completed. It is automatically ensured by the system that;

Primer anvil exists.

The flash hole exists.

Prime inserted right side up.

Primer depth is accurate.

Ring crimping is accomplished.

Extractor groove exists.

The cartridge mouth is circular.

The gunpowder exists and the level is accurate.

Bullet crimping is accomplished.

The cartridge length is accurate.

The cartridge's full form/loadability is accurate.

The cartridge weight is accurate.

At this point only surface imperfections such as corrosion, missing annealing, scratches, dents, etc. are left to be inspected. Therefore, this assembly line is equipped with manual inspection machines.

This assembly line with all the quality checks performed during the assembly produces accurate cartridges. The components that have dimensional and geometrical imperfections are already discarded from the system. Manual inspection is necessary only to detect surface imperfections. Manual inspection stations will be efficient to handle 200 cartridges per minute with two lines having one operator at each line.

Manual inspection stations are automatically fed by an elevator conveyor from the loading machine. Cartridges are lined up on a horizontal belt and conveyed in front of the operator. The cartridges rotate as they move on the belt for a 360° visual inspection enhanced by a mirror reflection under the horizontal belt. Click here for further information about the Manual Inspection Machine.

Automated Packaging Machine

The high-capacity assembly line culminates with an automatic packaging machine. This packaging machine is used in cases where ammo is stacked in cardboard boxes. Boxes are unfolded automatically and conveyed to the filling station. It not only provides continuous operation but also performs checks in that boxes are folded, glued, and filled accurately.

If there are pistol calibers also assembled in this line there will be a separate dedicated packaging machine that fills the pistol cartridges first in plastic trays, then into boxes.

Rifle calibers are stacked in cardboard boxes in an alternating order. Boxes are unfolded automatically and hot glued. Filled and sealed boxes are checked with a camera and weighed at the end of the line to make sure that the quantity in each box is correct.

Ammo packaging machines can be entirely re-designed according to the client’s preferences and the requirements of end users. Laser marking, inkjet printing, label applicators, palletizers, etc. can be embedded into the system based on the end-user’s logistics and storage requirements. Semi-automatic packaging systems also can be created where preferred. Click here for further information about the Packaging Machine.

Human Interface and Safety

The machines are built ex-proof following the ATEX Directive.

All the safety precautions are taken to safely handle primers and the gunpowder. Materials in the primer and the gunpowder feeding system are chosen accordingly.

The machines are designed for a minimum level of physical human interaction with the machine.

The doors of the machines are safely locked and the machines do not operate unless the doors are properly closed.

The system refuses to run when the air supply pressure is insufficient.

The system shuts down in case of a jam.

The real-time production count is displayed on the HMI screens.

The faults and their location and all the alarms are listed on the HMI screens.

All stations and their components are displayed on the HMI screens.

Conversion Tool Kits

It takes only one shift to replace the conversion tool kits of the entire assembly line.  After the conversion is completed, another shift may be spent for test runs. Basically in 2 shifts, the system will be ready to assemble the next caliber at full capacity.

We design and produce all the conversion kits at our factories. Therefore, we can guarantee the supply of parts for years. Furthermore, we can provide a complete set of conversion kits for new calibers that the client wants to add to the system.