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The High Cost of Defects in Ammunition Manufacturing
Ammunition manufacturers face one of the most strict and unforgiving quality landscapes in modern manufacturing. Every sealed round must perform flawlessly, survive storage, resist moisture, and deliver consistent ballistic performance. Even the smallest sealing defect can undermine all of those requirements.
When defects occur, the consequences go far beyond scrap or rework. Poorly sealed ammunition introduces major risks:
- Safety Hazards: Moisture intrusion, primer failure, or inconsistent ignition can create dangerous misfires or hangfires.
- Contract Compliance Issues: Defense and aerospace customers demand zero-defect performance and traceable quality assurance.
- Costly Recalls: Even a small batch failure can result in widespread recalls, brand damage, and regulatory action.
- Wasted Material and Labor: Defects discovered too late in the process waste casings, primers, adhesive, labor hours, and line capacity.
- Missed Delivery Deadlines: Rework slows production and can jeopardize contract renewals.
In a global market where demand is high but expectations are even higher, manufacturers cannot afford process variability—especially during the sealing stage. This is why the industry is increasingly shifting toward precision dispensing, UV curing sealants, and automated inspection systems that reduce defects and strengthen reliability across the entire production operation.
Hernon has emerged as a strategic partner to ammunition producers, offering integrated systems designed not just for speed—but for repeatability, accuracy, and defect reduction.
Common Causes of Sealing Defects in Ammunition Production
Sealing may appear to be a small part of the ammunition manufacturing process, but it has an outsized impact on product reliability. Defects are nearly always rooted in one of four core issues.
Poor Substrate Preparation
Clean and consistent substrates are essential for strong adhesion. Poor preparation can result from:
- Residual lubricants or contaminants
- Irregular primer or case mouth surfaces
- Dust or debris on the production line
Even minor contaminants can weaken the seal, allowing moisture intrusion or reducing long-term stability.
Slow or Variable Curing Processes
Traditional sealing chemistries often rely on thermal or ambient curing. These methods introduce variability because curing depends on:
- Temperature fluctuations
- Humidity changes
- Cure time windows
- Operator handling during partial cure
Slow curing also means rounds must sit longer before they can be packaged—leaving more opportunity for smearing, movement, or incomplete sealing.
Human Error in Inspection
No matter how skilled an operator is, human inspection introduces variability:
- Fatigue
- Subjective judgment
- Limited visibility at high speeds
- Inconsistent inspection standards across shifts
When defects are caught late—or not caught at all—manufacturers risk safety incidents, rework, or rejected batches.
Automated inspection eliminates subjectivity and ensures every round is evaluated using consistent criteria.
Solutions for Reliability: How Hernon Reduces Defects at the Source
Defect reduction is not achieved by solving just one issue—it requires a complete, integrated approach. Hernon’s system-based methodology ensures reliability through every stage of the sealing process.
Precision Dispensing Systems — Accuracy That Eliminates Variability
Precision dispensing is the foundation of reliable ammunition sealing. Hernon’s dispensing systems are engineered for:
- Exact volume control (down to microliters)
- Consistent, repeatable bead patterns
- Stable performance at high speeds
- Integration with multi-caliber production lines
By eliminating over-dispensing and under-dispensing, precision equipment directly reduces defect rates and material waste.
This technology ensures that every round—whether for training ammunition or critical military applications—receives the right kind of sealant it needs.
UV-Curing Sealants — Fast, Predictable, Consistent Sealing
UV-curing sealants are rapidly becoming the standard for ammunition sealing because they resolve many of the curing-related defects caused by slower traditional methods.
Key Advantages for Defect Reduction:
- Instant curing eliminates variability due to temperature or humidity
- Immediate downstream handling reduces smearing or bead movement
- High moisture resistance strengthens long-term reliability
- Predictable cure profiles ensure consistent seal strength
- Lower energy consumption supports lean manufacturing goals
Hernon’s UV-curable sealants are specifically formulated for ammunition applications, providing excellent adhesion, controlled viscosity, and fast polymerization under UV light.
Automated Inspection & Rejection — Every Round Checked, Every Defect Removed
Modern ammunition manufacturing requires more than sampling. Every round must be verified.
Hernon’s automated inspection technologies use high-speed cameras, sensors, and intelligent rejection mechanisms to evaluate each part before it leaves the line.
Benefits include:
- Real-time defect detection at full line speeds
- Instant rejection of noncompliant parts
- Removal of human subjectivity and fatigue
- Documentation for quality control and contract compliance
- Data-driven insights for process optimization
When integrated with precision dispensing and UV curing, automated inspection creates a closed-loop system that ensures quality from start to finish.
The Defense Contract Factor — Why Reliability Matters More Than Ever
Defense procurement cycles for 2026 and beyond are expected to emphasize:
- Zero-defect expectations
- Production automation
- Tighter documentation requirements
- Energy-efficient processes
- Predictable throughput and delivery schedules
Manufacturers relying on outdated sealing methods—or inconsistent inspection processes—may struggle to compete for future contracts.
Reliability isn’t just a manufacturing advantage. It’s a strategic differentiator.
Defense suppliers who implement precision dispensing, UV-curing sealants, and automated inspection position themselves as:
- More efficient
- More consistent
- More compliant
- More competitive for long-term contracts
By partnering with Hernon, manufacturers gain the ability to meet rising standards while increasing throughput and lowering costs—all without sacrificing quality.
Ready to Reduce Defects and Increase Reliability? Hernon Can Help.
Sealing defects are not inevitable. With the right systems, processes, and materials, manufacturers can achieve a new level of precision and reliability—one that meets the expectations of defense, aerospace, and commercial ammunition customers alike.
Hernon provides a fully integrated suite of solutions:
- Advanced sealants and UV-curing sealants
- Precision dispensing systems built for ammunition lines
- Automated inspection and rejection technology
- Engineering support for process optimization
If your goal is to reduce defects, increase throughput, and prepare your facility for next-generation defense contracts, Hernon’s sealing solutions are designed to help you get there.
Contact Hernon to explore equipment demos, sealant recommendations, and integrated defect-reduction strategies.
