BAE Systems projects 16-fold increase in 155mm shell production

UK company BAE Systems has developed innovative new approaches in the production of energetics and propellants to strengthen artillery supply chain resilience for the UK and its allies. These developments will deliver a sixteen-fold increase in production capacity of 155mm artillery shells when its new explosive filling facility at Glascoed, South Wales, becomes operational in the northern summer.

The new methods will use continuous flow processing to synthesise explosive material and remove the need for Nitrocellulose and Nitroglycerine, which are high in demand across global supply chains, in propellant production. As a result, the Company anticipates it will be able to produce sufficient explosives and propellants in the UK to meet UK Ministry of Defence and export requirements, with the initial phase of industrial capacity expected by the end of 2026.

“Our leap forward in synthetic energetics and propellant manufacture will strengthen the UK’s supply chain resilience and support our ramp up of critical munitions production to meet growing demand in response to the increasingly uncertain world we’re living in,” said Steve Cardew, Business development Director at BAE Systems’ Maritime and Land Defence Solutions. “It also supports economic growth through high-skilled jobs and potential export opportunities.”

These enhancements follow more than £150 million ($312 million) of investment by the Company in its UK munitions facilities since 2022. The Company has invested a further £8.5m in novel manufacturing methods over the last five years, leading to significant breakthroughs in the creation of next generation explosives and propellants.

A pilot has already demonstrated the technological breakthrough, producing the explosives in small batches. This technology would remove the need for a large-scale explosive factory. The new propellant formulation and associated manufacturing process have been demonstrated across a wide range of products from small arms to large calibre munitions.

The new technologies are intended to require lower investment and would offer greatly reduced running costs whilst providing enhanced safety in manufacture due to the continuous process meaning there is less explosive in process at any given time.