A century-old formula for British ammunition is being reengineered, and it could be a game-changer for the future of UK defence manufacturing.
For over 100 years, British-made ammo has relied on two volatile chemicals: nitroglycerine and nitrocellulose. Effective, yes, but dangerous to produce, hard to store, and increasingly dependent on fragile global supply chains.
Now, in a major shift, BAE Systems is rolling out a revolutionary new process that promises faster, safer, and more reliable ammunition production, all made in Britain.
From Batch to Flow: Rethinking Explosive Manufacturing
At the heart of the change is a move from traditional batch production to continuous flow manufacturing, a method that allows high explosives like RDX to be produced more safely and efficiently on home soil.
“Conventionally, high explosive is manufactured in large-scale batches, meaning you need a massive facility and a wide safety perimeter,” explained Steve Cardew, BAE’s Business Development Director.
“We’ve changed that. Now, we use a smaller facility running continuously, delivering better output, at a lower cost, and with significantly less risk.”
Ditching Dangerous Chemicals
But it’s not just how it’s made, it’s what it’s made of.
BAE is also phasing out legacy propellants such as nitroglycerine and nitrocellulose. Instead, they’re shifting to a more stable and streamlined formulation that still uses RDX, but eliminates the most volatile ingredients.
“We’re simplifying the supply chain,” said Cardew. “By removing nitroglycerine and nitrocellulose, we’re using fewer ingredients, it’s safer, easier to scale up, and still delivers the same performance.”
Answering the Ukraine Wake-Up Call
The shift comes at a critical time. The war in Ukraine has exposed serious vulnerabilities in global munitions supply chains, particularly for high explosives and propellants.
“Today, we’re reliant on overseas suppliers for both,” Cardew admitted. “That carries risk. This new approach helps us build much greater UK resilience, and that’s absolutely vital to support our armed forces.”
Major Expansion Underway
While the new tech is still scaling up, BAE isn’t waiting around. The company is also massively increasing traditional output, including a 16-fold increase in 155mm artillery shell production at its South Wales plant, where state-of-the-art automation is already being installed.
“It’s a really exciting facility,” Cardew said. “Highly automated, high-volume, and capable of delivering huge quantities of ammunition for British troops.”
Deliveries from the upgraded factory are expected to begin this summer.
Building a Stronger Defence Base at Home
The goal? More than just increased output. BAE’s transformation aims to make Britain less dependent on foreign suppliers, while reinforcing its defence industrial base for the long term.
In a world where the ability to sustain your own firepower matters more than ever, this could be one of the most important, and quietly revolutionary, changes in British defence production in decades.
