This write up is geared towards introducing someone to the processes and timelines for developing a load for the commercial market. I realize this will not have a lot of importance to the hobby handloader, but it will help outline some of the testing that is done prior to the final product hitting the shelves. There will be a series of write up that delve deeper in these tests.
If load development is something that will be done on a frequent basis then it is wise to develop some sort of standardize template for managing the project. There are several Project Management Softwares to choose from. A simple and free software to use is Gantt Project. This may be downloaded here.
I will be using Gantt Project to outline a standard load development project, from start to first production run. If you are not familiar with Gantt Charts or project management, hopefully this will serve as a good introduction to help manage a successful load development project.
For this project we will assume that it is a SAAMI Cartridge that is readily available. We also sourcing a bullet that is already on the market. In instances where this is a wildcat cartridge, or a new bullet design, there are additional lead times that must be taken into account.
Preload Development Activities
Project Targets
Before you can develop a load we need to establish what the load is going to be. These targets are going to typically be set by product management. The basis for the specs are usually based on existing SAAMI Loads.
For Example – “We feel there is a hole in a our 45 ACP product line. We’d like to offer an economy 185gr FMJ Target Load to our line up as it is popular with pistol shooters. “
“Based on existing SAAMI loads we’d like to a target velocity of 995fps @ 21.0kspi.”
Product Management will also set forth a target price per round and a target date. Input from the R&D Team, Purchasing, and other departments is usually needed. The targets should be captured in a document so that it can be communicated to the various teams involved in the development process. It is important that this document is vetted as it will help determine the success or failure of a project.
In short a proper Load Development Objectives should at a minimum identify the following:
- Target Velocity
- Max Pressure (SAAMI MAP or CIP PMax)
- Accuracy Requirements (# of Shots, Max Group Size, Range)
- Target Market (CIP or SAAMI)
- Production Cost
- Retail Cost
- Any other requirements (Low flash, bullet expansion, ect.)
Before the Load Development Objectives are finalized a Bullet Chamber Fit model and drawing should be established. This will allow you to check to make sure that a selected bullet will chamber in the selected cartridge. Failure to check this, especially when trying something new, may end up costing money and time if the selected bullet does not fit within the intended chambering. This will establish the target COL, which will be used during load development. A write up on a Bullet Chamber Fit Modeling can be found here.
There are several long lead time items that will need to be ordered and received before shots can be fired. The assumption for this write up is that there is already a lab and load development work has taken place before and the lab will be making pressure and velocity measurements. The sooner the project targets are finalized the sooner orders can be placed.
Lab Equipment
Some of the longest lead time items will be receiving the a P/V Barrel, Transducer, and if needed a Calibration Adapter. Plan on 8-10 weeks at minimum to receive everything. Since these are usually the longest lead time items, they will determine the soonest you can begin testing loads.
Component Sourcing
Component sourcing is everything you’ll need for load development except for the powder. A typically load development, done commercially, will require between 1,000 to 1,500, shells (AKA Brass), bullets and primers. It seems like a lot, but in future write ups we will cover the actual testing. Lead times on brass, bullets and primers can be highly variable depending on what you are actually trying to source. It is best to get this ordered and on the way as soon as possible.
Depending on what you’re trying to source, 4 weeks is realistic. Believe it or not 1.5k shells is nothing compared to what a manufacture’s production order is.
Test Powder ID and Sourcing
The purpose of the load development is to find the best powder or propellent that meets or exceeds the Project Targets. In order to ensure that you have screened as many of the powders on the market, a load developer will want to source a sample of as many powders as he or she can get their hands on.
At a minimum 1lb of powder should be ordered at a time. Even if the powder doesn’t make it through screening it will be useful to have in stock for a future powder screening. If the powder is selected for a full load development, several pounds of powder may be required for a large magnum round.
Lead time on powders can vary, depending on if a distributor has it in stock or if it has to be shipped in from out of country. As with the components 4-6 weeks for ordering and receiving the powder is a fair estimate.
Test Firearms
Three to four test firearms should either be on hand, or be ordered. Allow for 2 to 4 weeks for ordering a new firearm. If the firearm you want is popular and new to the market then lead times could be considerably longer. As a general rule of thumb you want firearms that are representative of typical guns that the cartridge will be fired from.
For a 45 ACP, you will likely want to include a 1911, and a Glock , as those are two of the most popular 45 ACP’s on the market. You may consider including an Pistol Caliber Carbine, as those are increasing in popularity.
When doing a load development for 6.5 Creedmoor you’ll want one or two AR-10 firearms of different brands. You’ll also want at least one bolt action.
Firearms for a 45 Colt, might include a Single Action Army, a lever action firearm, and a firearm that fires both 45 Colt and .410 Shot shells.
Competitor Samples
It never hurts to figure out what the other guy is doing. Ammunition has to ship ground and it usually takes a week or two to get to you.
Loading Equipment
Do you have the dies you need to load for this cartridge? This should be ordered the same time as the competitor samples as they’ll usually ship from the same companies that you order reloading supplies.
Production Gaging and Tooling
Once everything has been ordered there will typically be a period where you are waiting for everything to arrive. At this time is it prudent to look ahead in the project. If this load is a sure thing, you may want to design the gaging and tooling needed for production. Machine shop times can very but it is not uncommon for machine shops to take 8-12 week at a minimum. Anything quicker is considered emergency work and they charge extra for that.
Typically allow yourself a week to two weeks to complete all of the design work needed. This is assuming it is gaging, and a few specialize tool heads for a Camdex 2200.
Charting out the Pre Loading Activities look something like this:
Load Development
As long as the Pre Load Development activities have been completed, the actual load development work happens very quickly. This is where all the fun truly happens. We will have write ups that detail all of the activities that we outline, but for now here is the rough outline and sequence of testing.
- Prepare Load Development Template
- Shell (Brass) Calibration (If Required)
- Barrel Calibration
- Powder Screening
- Powder Selection (Typical the top five or six powders)
- Initial Hot – Cold Testing (Load and Shoot) (Involves 24hrs temp conditioning)
- Neck Tension Testing
- Load Sensitivities ( Takes about a day to load all the rounds) (Involves 24hr temp conditioning)
- Shoot Sensitivities (Takes about a day to shoot all the rounds)
- Prep Loads for Function Testing (Involves 24hr temp conditioning)
- Competitor Evaluation (Depending on what your looking for this can be as simple or as complex as you make it.)
- Prepare and Finalize the Development report
- Present Report for Production Team Sign Off
- Follow up Testing – Present findings (Not always needed)
Load Development is a flurry of activity that typically lasts between 3 to 4 weeks. There are some activities that can happen in parallel, and the time it takes is highly dependant on the skill of the technician who is doing the work. The key to a fast and efficient load development is making sure all the prep work is completed in the Pre Load Development Stage.
The main deliverable for the Load Development is a completed report that outlines which are the top three most suitable powders for a load. These are selected based on the performance in the sensitivities testing. Powders which spike to unsafe pressures (SAAMI Min Proof Individual) during hot or cold testing are usually ruled out. Safety concerns are always addressed first, and then whether or not the performance of the load meets the Load Development Targets.
While load development will screen 20 or more powders for load development, only two or three powders will make it to the Experimental (EX) Runs.
Experimental Runs
The Experimental (EX) Runs are short runs of typically no more than 5,000 pieces each. The purpose of the EX Run is two fold;
- Evaluate the ability of load equipment to manufacture the load.
- To provide ammunition for additional testing to ensure manufacture rounds meet the Load Development Targets.
Rarely does ammunition loaded in an EX Run leave the manufacturing facility. It is almost always consumed in testing.
In order to perform a successful EX Run the Pre Load Development Activities for Tooling and Gaging must be completed. The EX Run cannot commence until sufficient quantities of Bullets, Brass, Powder and Primers have arrived. These are typically the long lead time items. Once a handload has been signed off and an EX Run approved this needs to be communicated to Purchasing so that product can be ordered.
Depending on the level of risk a company is willing to assume, EX Run Quantities of the Bullet, Brass and Primers may be ordered during the load development stage. Powder will nearly always be sourced after the Load Development Report is signed off. There have been times when powder was sourced from the local Sportsman’s Warehouse, just because it was available and quicker. However typically powder is sourced from a Distributor or directly from the Manufacturer.
4 to 6 week lead time on powder is not uncommon. If the powder must be sourced overseas this lead time can easily double. Powders which are only produced on a limited basis can also increase lead time. For this reason powder availability should be something understood during the Load Development stage.
It is not uncommon to order virgin brass pre primed. This simplifies the logistics of ordering both primer and brass and then priming them on site.
When planning the EX run, assume that your loading machine will be under utilized for at minimum of a day. If you are using a Camdex 2200 that typically runs at 60 Parts Per Minute (PPM) plan on it running at 10 PPM average. When it’s actually running it might run faster then 10 PPM but the amount of set up and down time on an EX Run can be staggering. Kinks in the tooling, combined with a new loading, with a potentially new powder, is the recipe for bugs. Typically a second EX Run will go faster then the first as the only substantial change is the powder. .
The deliverables for an EX Run are three fold;
- Production Report (Can they produce it, or do they need more tooling?)
- Quality Report (Do the rounds meet quality standards)
- Lab Report (Are the rounds safe, and do they meet Load Development Targets?)
We will go into more detail on some of the Quality and Lab tests and reporting that is done in future write ups. Many of the tests the Lab will run mirrors the tests that were run at the the Load Development stage, they are just shot in greater quantity. This helps build confidence that the round will perform safely, and as advertised in the field.
When the reports for the EX Run are reviewed and signed off a Trial and Pilot run is ordered. This Trial and Pilot run is very similar to an EX Run except the ammunition will likely be released to the consumer. If two or more EX Run’s were performed then the results will be reviewed individually. It is not uncommon to have two good powder candidates. Typically the powder that best meets the Load Development Targets will be chosen. The powder which is not selected will usually be approved as an secondary powder, for use should the primary powder be unavailable.
Trial and Pilot Runs
Trial and Pilot (T&P) runs are typically the first true production runs, and production quantities of Brass, Bullets and Primers need to be sourced. As with the EX Run, these may be sourced as part of the Pre Load Development activities, it all depends on the level of risk a company is willing to assume.
If the EX Run fails due to the bullet or brass not being compatible with the loading equipment, and a different component needs to be sourced then having T&P quantities of a defective component is less than ideal. To be fair this is a pretty rare event. While it is definitely possible to receive product that is of substandard quality, the liability for that is usually on the manufacturer.
T&P Runs are essentially a second EX Run but with greater quantities of product produced. The same testing is performed with a T&P run as is performed with an EX Run. The same review is conducted at the end of a T&P Run as is performed with an EX Run. Once the review is completed and no issues turn up, the load is approved for general production.
Wrap Up
The purpose of this write up was to provide an introduction to, and an example of how an ammunition company may conduct a load development. In many ways this is an introduction to the many aspects of professional load development, as well as introducing a tool for managing the project. This has all been based on my experience in conducting several load developments.
Lead times are highly variable, and depending on the project and the level risk a company is willing to shoulder, many items can be done in parallel. However the time from a request for a new load from Product Management to the load hitting store shelves is typically 9-12 Months.
Hopefully this is useful to you. I have provided the full Gantt Chart below.
Remember this is one project, and ammunition companies rarely only have one project going on at a time. Which means you are typically working with limited resources, trying to do keep up with normal production as well as accommodating EX runs can be taxing and will likely add to lead times.