turnkey ammunition plant solution for … · waterbury farrel began shaping the course of history...

TURNKEY AMMUNITION PLANT SOLUTION FOR UKRAINE

The CompanyWaterbury Farrel began shaping the course of history with innovative machinery design in 1851 and developed an impressive product portfolio of presses, rolling mills, drop hammers, cold heading machines, slitters and shears.

Today Waterbury Farrel is a division of Magnum Integrated Technologies Inc, a premier multi-national corporation with over 160 years of product and technology experience. Headquartered in Brampton, Ontario, Canada, the company designs and manufactures high quality machinery for the metals and ammunitions industries. Under our ISO 9001-2008 certification, we combine our process and machinery expertise to build fully integrated turnkey manufacturing facilities.

A Strong PrincipleWaterbury Farrel provides arsenal equipment and services offering complete turnkey ammunition factories. Our international reputation for innovative and reliable processes and equipment production facilities is demonstrated by a century’s worth of excellent uptime safety records.

Defining QualityDelivering measurably superior machines means maintaining the strictest quality standards. It is for this reason that Waterbury Farrel is the NATO and International Military standard for ammunition production. Each round is produced to exact tolerances to ensure that every component is uniform, resulting in high accuracy in each bullet to provide excellent performance.

It takes skill and experience to design and build machines that will hold the tolerances that you need day in and day out, year after year. Waterbury Farrel is the global manufacturing leader with the ability to provide turnkey ammunition factories meeting the customers’ requirements for quality, reliability and return-oninvestment.

Turnkey Ammunition Solutions

Boosts Performance

Custom Designed

Quick turn-around

Maximized output

Increased efficiency

High quality products

Extended plant lifetime

Higher intellectual capital

Fastest return on investment

The Turnkey Process

We define the project needs, the timeline, equipment requirements and budgets.

We design the entire plant around a suitable process layout that meets the current and future product mix.

All machinery is designed and built to custom requirements to ensure that a high output of quality product is maintained.

We provide the construction management team

All machinery is witnessed in the factory prior to shipment to the plant site to ensure a quick implementation.

We take complete responsibility forthe project taking the guesswork and the long startup out of the equation.

A turnkey contract with Waterbury Farrel provides flexible solu-tions to suit your spe-cific needs.

Commissioning and Start-upWaterbury Farrel coordinates activities between the client and engineering, procurement and construction teams early in the project life cycle in order to organize the activities for a quick and successful start-up. We place the best people on site to handle the commissioning to ensure that performance requirements are met and the facility achieves a rapid ramp-up.

Turnkey Production PackageWaterbury Farrel will supply single machines, multi-machine customized packages up to entire integrated plants with fully-developed and fine tuned tooling. This ensures single-point responsibility for specialized part production via integrated press and tooling supply.

Construction ManagementWaterbury Farrel plans, executes and completes projects by applying well-developed systems that focus on facility start-up. Waterbury Farrel helps clients deliver their project objectives by developing and implementing strategies using the best people, practices and technologies. We focus on a high level of safety, performance and quality while meeting cost and scheduling targets.

Magnum has over 160 years of technology experience offering solutions for industry.We provide quality-engineered designs as well as turnkey solutions for a variety ofapplications.

Magnum Integrated Technologies Inc.

Quality Assurance

Nuclear Certification

ISO 9001-2008 Certification

Controlled Goods Certification

Converting Copper & Brass strip to Quality parts

Process Experience

Begins

Ammunition machinery

begins

Spanish/ American Civil war

Major supplier of munitions machinery

1920’s

expand machinery

selection

Rolling mills, stamping presses

Develop Silicon Steel Rolling

process

Supply USA & UK munitions Factories

1950 - 1975

Ammunition factories built

around the world

1980 – 2012

Develop many innovative processes

High efficiency systems

1871 18711871 19541955

History

Waterbury Farrel

Ammunition equipment manufacturing started during Spanish-American War

Became the prominent supplier during World War I

During World War II, WF was the major supplier of ammunition machinery to

England & the US Government as well as their contractors.

Provided Licensing to manufactures of ammunition equipment

High efficiency machines were introduced to the growing civilian market

Supplied complete ammunition lines, equipment, entire ammunition plants and

system development and feasibility studies to Arsenals around the World

History

Waterbury Farrel

Waterbury Farrel was incorporated as the Farrel Foundry Company in 1851

Re-incorporated as “The Waterbury Farrel Foundry & Machine Co.” in 1880

1920’s thru 1940’s Waterbury Farrel expanded its lines of Heading Machinery,

Rolling Mills & Stamping Presses

In 1958 Waterbury Farrel was acquired by Textron, Inc.

Since 1993 Waterbury Farrel is owned by Magnum Integrated Technologies

History

High Speed presses producing cup shaped product such as ammunition components, pen barrels, flashlight, lipstick cases, nut

covers, etc…

Machinery Manufacturing

100% factory approved prior to shipment

Optical measure and weight test of each component

Precision Mechanical Press Manufacturing

Waterbury Farrel Ammunition

Process Development

Operations Management

Installation & Commissioning

Feasibility

EPCM Solutions:

Project Management

Engineering &

Procurement

Assembly machines

Quality Assurance

Process treatments

Inspection Machines

Machinery Solutions:

Component

Manufacturing

Explosives production

Stiletto Systems Ltd. is an engineering companyled by internationally experienced team whichhas considerable knowledge in ammunition techno-logy development and turn-key delivery of plants.

Stiletto Systems provide local country withcomplete set of all ammunition drawings of smallcalibers, ballistic laboratory and firing rangefacilities , production plant layout and test tables.Develop for customer technology patents andtransfer the IP ownership rights.

Introduce to customer a disruptive ammunitiontechnology solution for local supply contracts andinternational exports.Establish local country as a major innovator to themanufacture of ammunition.

Stiletto Systems Ltd. ammunition are developed tooffer a step-change in performance and capability,allowing end user operate production facility moreeffectively and safely.

Stiletto Systems Ltd. - engineering company

3D ammunition Plant layout

Armour-piercing bullet ammunition

1. Sniper rifle cartridge, caliber 7,62 mm with armor-piercing bullet (bullet with hard-alloy core, cartridge index 762BS51).

Cartridge specifications

7,62 х 51

Powder, cased With armor-piercing bullet «БС»

Caliber 7,62 х 51 mm Bullet weight (mb) 13,1 g Weight of the armor-piercing core with accelerator (mсу)

9,5 g Ballistic coefficient of the bullet (С)

4,7 m2/kg Initial speed of the bullet from barrel 700 mm long (V0)

790 m/sec Lethal range (Х) for rival’s manpower without individual protection means the bullet preserves

Up to 4500 meters

Volume of charge chamber in the cartridge (W0)

0,0033 dm3 Weight of powder charge (ω)

3,0 g Type of powder “VihtaViori” № 540 (Finland) Maximum crusher pressure in the barrel

Not more than 3100 kgs/cm2

Cartridge weight 27,4 g Accuracy for 700-mm barrel at the distance of 200 m

R100 not more than 3,5 cm

Bullet’s armour effectiveness

Not less than 80% penetration from a barrel not less than 700 mm of steel plate armor with

hardness not less than 480 HB (BRINELL) 20+0,5

mm wide established at an angle of 90° to the horizon, at the distance of 150

m. Cartridge components:

Capsuled (Boxer-type capsule) case (case material is brass – Cu 70%, Zn 30%) on the bottom of which there is a marking (plant/factory number and year of cartridge production);

Bullet, Hard-Alloy Core-type, comprising of tombac cover (Cu 90%, Zn 10%), lead jacket (lead С0) and hard-alloy core (material- UF10); and progressive burning powder charge.

Cartridge assembly includes sealing with colorless sealer allowing cartridge performance in inclement and wet conditions.

Cartridge Specifications of 9/0 х 19 mm “LUGER” Powder, cased, rocket with armour-piercing bullet

Bullet weight (mob) 6,1 g Weight of the armour-piercing core

with accelerator (mсу)

Ballistic coefficient of the bullet (С) 22,6 m2/kg Initial speed of the bullet from barrel 150 mm long (V0) 530 m/sec

The bullet preserves the lethal range (Х) for rival’s manpower without individual protection means

Up to 600 meters

Volume of charge chamber in the cartridge (W0) 0,00065 dm3 Weight of powder charge (ω) 0,52 g Type of powder “VihtaViori” 3N37 (Finland) Maximum crusher pressure in the barrel Not more than 2900 kgs/cm2

Cartridge weight 10,7 g Accuracy for 150 mm barrel at the distance of 25 mm R100 not more than 5 cm

Wear resistance in single fire mode Not less than 20000 shots prior to 10% decrease in initial speed

Bullet’s armour effectiveness Not less than 80% of penetrations from the number ofqualifying firing from weapon with the length of the barrel not less than 130 mm steel plate armours with hardness not less than 480 HB (BRINELL) 6+0,5mm wide established at an angle of 900 to the horizon, at the

distance of 25 m

Cartridge components:

Capsuled (Boxer type capsule) case (case material is brass – Cu 70%, Zn 30%) on the bottom of which there is a marking (plant/factory number and year of cartridge production).

Bullet, «Hard-Alloy Core»-type, comprising of tombac cover (Cu 90%, Zn 10%)and hard-alloy core (material- UF10);

Progressive burning powder charge. Cartridge assembly includes sealing with colorless sealer ensuring cartridge performance in inclement and

wet weather.

Calibre 9,0 х 19 mm

Stiletto Systems Ltd. Team Owns International Patents and IP Rights

NATO metal boxes M2A1 are used as secondary packing for all produced ammunition

Turnkey solutions for Complete Cartridges, Cases, Projectiles and Primers

Complete Ammunition Line

Entire plants facilities

System developments

Feasibility study

Separate Production Line

Project Portfolios

Worldwide Supply of Munitions Factories

For Pistol, small & medium caliber bullets & grenades

Canada

United Kingdom

Taiwan

Thailand

Philippines

Israel

South & Central American Countries

African Countries

NATO Member Nations

EPC Portfolio

Ammunition Machinery Manufacturing

Waterbury Farrel Factory Dec 6, 2013

Primer Insertion Primer Insertion PLC

Lead Slug Header Slug Header

Machine Assembly Machine Assembly

Blank & Cup Machine CommissioningBAM

Delivering cost effective results to your bullet supply chain

0.38 cal

0.40 cal

0.45 cal

0.380 cal

5.56mm / 0.223 cal

5.45mm

7.62mm / 0.308/ 0.30 cal

0.50 cal / 12.7mm

14.5mm

Pistol & Small Caliber Ammunitions

Engineering, Construction, machinery supply, installation, commissioning , startup and training of personnel

Taking your project from concept to reality

EPC Portfolio

Typical Process Layout

Floor plan layot for two lines production

Pistol Case Manufacturing

General Plant Layout – Pistol Line

General Plant Layout – Rifle Line

General Plant Layout – Cup Manufacturing Line

•Blank & Cup Presses

•Initial Forming Case Presses

•Final Forming Case Presses

•Ejector Groove & Mouth Trimming Machines

•Bullet Assembly Machines

•Primer/Anvil Stamping Presses

•Primer Assembly & Loading Machine

•Gage and Weigh Machines

•Wash & Dry Machines

•Slug & Steel core Header

•Primer Insertion, Crimping & Varnishing Machine

•Cartridge Loading Machine

•Bullet Polishing Machine

Ammunition Equipment & Systems•Packaging Machine

•Laser Etching Machine

•Grenade Cone Presses

•Grenade Re-strike Presses

•Grenade Cone Presses

•Annealing Units

•Pickle, Lube & Dry Machines

•Low Temperature Annealers

•Quenchers

•Material Handling System

……. and many more, as needed by the process

The presses that shape and form the copper and brass to the desired components.

The Heart of the Process

Ammunition Machinery

•Ammunition Machinery

Tooling

Other Systems

Shooting Range Equipment

Laboratory Equipment

Conveyor System

Propellant Feeding System

Tapers Radii

OPTIONAL SENSORS

DefectsDetected:

Defective Plating

Heat Treatment

Mass Differences

Eddy-C rru ent:

Uses electromagnetic force field to

detect flaws i cn onductive material

Vision System Option:

Singl ve i cew eram a with

sophisticated image

analysis software that

minimize ss urface and

lightin vg ariations. Used

for mouth and primer

inspection.

FeaturesMeasured:

Defects Detected:

Head Di ma eterM ssi ing, Damaged or Inverted

Primer

Mouth Diameter Defective or M ssi ing Head Stamp

P imr er Pocket Di ma eter Cracks

Primer Hole Diameter Damage

Roundness Presence of Waterproofing

3D-Primer Depth Sensor:

The Gi 3D primer pocket

depth measurin sg ystem

utilizes two high resolution

CC cD erma as with a precision

triangulation laser profiler to

illuminate and measure the

dept oh f the primer pocket.

As the case travels down the

v-track the 3 precision

sensors are triggered to

make the measurements.

FeaturesMeasured:

Primer PocketDepth

Anvil Height

Tapers Radii

FEEDERS

Turn-key, flexible feeder systems with interchangeableplates.

Step feeders used for projectiles

Cup feeder with automatic metering

Hang by the head vibratoryeeder for rimfire ammunition

PROTOTYPA-ZM, s.r.o.

STANDARDS FOR TESTING OF PROTECTIVE MATERIALS

PROTOTYPA

BASIC STANDARDS:

• STANAG 2920 – BALLISTIC TEST METHOD FOR PERSONAL ARMOUR

MATERIALS AND COMBAT CLOTHING (31 July 2003)

• AEP-55 PROCEDURES FOR EVALUATING THE PROTECTION LEVEL OF

ARMOURED VEHICLES (August 2011)

• NIJ Standard–0101.06 Ballistic Resistance of Body Armor (July 2008)

PROTOTYPA TEST FACILITIES

PROTOTYPA OFFERS TESTING:

• V50 TESTS STANAG 2920 – (CALIBRS 9mm; 5,56mm ; 7,62mm ; 12,7mm ;

14,5mm , 23mm ; 25mm ; 30mm ; .22FSP ; .30FSP ; .50FSP and 20mm FSP).

• YAW MEASUREMENT

• HIGH SPEED CAMERA MOVIE

• EPVAT MEASUREMENT

• ACCURACY MEASUREMENT

PROTOTYPA BALLISTIC TEST EQUIPMENT – PROTECTIVE MATERIALS

PROTOTYPA TEST EQUIPMENT

Velocity Light gates

Test gun

Remote

control

ProtectionRetention

system

Witness plate

Testing according to:

• NIJ 0101.06

• STANAG 2920

• AEP-55

• special projectile simulated EFP

UZ-2011 Universal Ballistic Breech

UZ-2002

Ballistic BreechSpecification:

-maximal caliber: 12,7mm

Specification:

-maximal caliber: 338 Lapua Magnum

UZ-2010 Universal Ballistic BreechSpecification:

-height: 165 mm

-length: 1200 mm

-width: 280 mm

-total mass: 125 kg

-maximal caliber: 25x137 mm

Ballistic Breech

Specification:

-maximal caliber: 35x228 mm

HIGH SPEED BALLISTIC GUNManufactured ballistic barrels:

-22 FSP, 30 FSP, 50 FSP and 20m FSP

-FSP Muzzle velocity up to 1800 m/s

Fragment simulator caliber 20mm:

-20x102mm Muzzle velocity 800 … 1300 m/s

-20x139mm Muzzle velocity 800 … 1300 m/s

-20mm PROTOTYPA FSP Muzzle velocity 1200 … 1800 m/s

Specification:

- Measuring the projectile velocity:

- range: 10-2500 m/s

- accuracy: 1%

- Projectile caliber range 4 up to 40 mm

- WI-FI, Intelligent BMS Software

INTELLIGENT VELOCITY LIGHT GATES

MAIN COMPONENTS

EPVAT MEASUREMENT SYSTEMElectronic Pressure Velocity & Action Time

MAIN COMPONENTS

PRESSURE SENSOR

6215 KISTLER QUARTZ HIGH PRESSURE SENSOR

•The front sealed high pressure sensor suitable for ballistic pressure measurement up to 6 000 bar.

•Sensor Type 6215 has been accepted by NATO (AC/225 LG/3-SG/1) and is integrated part of NATO Standardization Agreements (STANGAGs) and Manner of Proof and Inspections (MOPIs).

MAIN COMPONENTS

ACQUISITION UNIT

2519A KISTLER TRANSIENT RECORDER

•High end transient recorder suitable for ballistic applications.

• NATO and CIP standards

• Easy to use

• Maintenance free

• User friendly software

•Standard assembly:• 4 charge inputs

• 4 voltage inputs

MAIN COMPONENTS

VELOCITY LIGHT GATES

2521A KISTLER TRANSIENT LIGHT SCREEN

•Weatherproof Light Screen Type 2521A is an accurate electronic device for measuring velocity. It is designed for working in harsh outdoor environments (wet, dusty, hot or cold climate with water condensation or heavy rain).

•Type 2521A works in the infrared spectrum.

MAIN COMPONENTS

ACTION TIME

SIGNAL START•Insulated firing pin•Accelerometer

SIGNAL STOP•Port pressure sensor•Muzzle sensor•Flash detector

PRINCIPLE OF FUNCTION

BA CONTROL SOFTWARE

MODELS AND TECHNICAL SPECIFICATION

STZA-10 FIRING REST FOR WATER TANK

TECHNICAL SPECIFICATION

height 490 mm

length 1185 mm

width 350 mm

total mass 54 kg

maximal caliber 7,62x54R

STZA-12M1 MOBILE FIRING RESTTECHNICAL SPECIFICATION

maximal caliber 12,7mm

height 1000 mm

length 1270 mm

width 700 mm

total mass 350 kg

transport tow bar 8 kg

recoiling parts mass 18 kg

maximum recoil stroke 75 mm

elevation range 5

azimuth range 5

clamping strip pitch 230 mm

STZA-12BM1 MOBILE FIRING RESTTECHNICAL SPECIFICATION

height 1009 mm

length 1238 mm

width 700 mm

total mass 350 kg

towing bar mass 8 kg

elevation range 5

azimuth range 5

clamping strip length 230 mm

STZA-12BLVL MOBILE FIRING REST

Height 395 mm

Length 1080 mm

Width 430 mm

Mass 71 kg

elevation range 5

azimuth range 5

STZA-13 MOBILE FIRING RESTTECHNICAL SPECIFICATION

height 1070 mm

length 1350 mm

width 970 mm

total mass 500 kg

elevation range 5

azimuth range 5

transverse mechanism 150 mm

maximal caliber 12,7mm (14,5mm)

STZA-14 FIXED FIRING RESTTECHNICAL SPECIFICATION

height 1100 mm

length 1325 mm

width 740 mm

total mass 350 kg

elevation range 5

azimuth range 5

maximal caliber 12,7mm (14,5mm)

height 1040 mm

length 1570 mm

width 1000 mm

total mass 815 kg

elevation range 5

azimuth range 5

transverse mechanism 250 mm

maximal caliber 20 mm

height 1045 mm

length 1270 mm

width 740 mm

mass 1300 kg

elevation range 5

azimuth range 5

STZA-25T FIXED FIRING REST CUSTOMIZED

Height 1101 mm

Length 1275 mm

Width 1080 mm

Mass 1465 kg

elevation range 5

azimuth range 5

STZA-30 FIXED FIRING REST CUSTOMIZED

height 1035 mm

length 1400 mm

width 860 mm

Total mass 2050 kg

elevation range 5

azimuth range 5

ADAPTORS

PISTOLS AND REVOLVERS

ADAPTORS: UNIVERSAL (FUNCTION TESTING) ONE PURPOSE (ACCURACY TESTING / ZEROOING)

ADAPTORS

RIFLES, AUTOMATIC RIFLES, SHOTGUNS

ADAPTORS: UNIVERSAL (FUNCTION TESTING) ONE PURPOSE (ACCURACY TESTING / ZEROOING)

ADAPTORS

REFICO – REMOTE FIRE CONTROL

Specifications:

firing finger stroke adjustment range 2 - 25 mm

firing finger force adjustment range 20 - 120 N

ADAPTORS

REFICO – REMOTE FIRE CONTROL

Parameters:

-Stroke

-Force

-Velocity

-Shot limit

-Delay

-Mode (single/burst)

-Mounting (left/right)

DOPPLER RADAR SYSTEM DRS-1

BMS Software DRS-1 Assembly

TUMBLER DRUM TD-2014Specification:

-test temperature: 65 ± 2 °C

-tumbler drum rotation: 5 ± 1 rpm

-test relative humidity 80 ± 5 %

-NIJ Standard-0101.06

-speed, temperature and humidity control by PC

Specification:

-height: 926 mm

-length: 960 mm

-width: 850 mm

-total mass: 150 kg

BACKING MATERIAL FIXTURE, HOLDER

Holder specification:-inside dimensions: 610x610x140 mm

-backing material: Roma Plastilina No.1

-total mass: 102 kg

Fixture specification:

-dimensions: 350x700x850

-total mass: 35 kgHolder Fixture

HARD ARMOR DROP TESTER HADT-1

Specification:

-height: 1575 mm

-length: 500 mm

-width: 500 mm

-total mass: 130 kg

-NIJ Standard-0101.06

HARD ARMOR DROP TESTER HADT-1

Specification:

-height: 2685 mm

-length: 2180 mm

-width: 730 mm

-drop height: 2000 mm ± 15 mm

-sphere weight: 1043 g ± 5 g

-sphere dimension: Ø 63.5 mm ± 0.05 mm

-fixture head weight: 100 kg

-total mass: 160 kg

-Conducting validation drops into

the backing material.

-Fully adjustable drop height.

-Easy aiming.

-Easy handling.

-Mobile.

HEAD FORM HF-1Specification:

-height: 300 mm

-length: 250 mm

-width: 250 mm

-helmets size: 7 ¼"

-total mass: 19 kg

Option A Option B

SAMPLE HOLDER SMJFSpecification:

-height: 720/ 761 mm

-length: 670 mm

-width: 640 mm

-total mass: 115/145 kg

-size of clamped samples: 500x500/400x400 mm

-size of witness plate: 0.5x545x600 mm

-material of witness plate: 2024-T3 or

2024-T4 aluminum alloy

MOTOR-DRIVEN TARGET TABLE MDTT-2014Specification:

-height: 700-1300 mm

-length: 1400 mm

-width: 2100 mm

-total mass: 1310 kg

-revolving range/step: 360º/5º

-transversal movement: ±300 mm

-maximum weight on table: 1000 kg

-maximum caliber: 12,7 mm

Lowest position Highest position

MOBILE FIRING REST STZA-16M1Specification:

-height: 900-1500 mm

-length: 1400-1450 mm

-width: 1055 mm

-total mass: 630 kg

-vertical movement: ±300 mm

-transversal movement: ±300 mm

Lowest position Highest position

MOVING GUN TABLE GM1Specification:

-size – working position: 5000x3000x4000 mm

-total mass: 3000 kg

-elevation range: -30° ÷ 0°

-transversal movement: 0 … 4000 mm

-vertical movement: 1000 … 3500 mm

-maximum caliber: 12,7 mm

Remote control

Remote

firing box

Panel Remote control

Prototypa - ZM, s.r.o.

Prototypa-ZM, s.r.o.

OnPower

YAW MEASUREMENT SYSTEM PYAWMS

Specification:

-active area - dia: 400 mm

-projectile velocity up to : 2500 m/s

-length of projectile up to: 180 mm

BMS Software

Your benefit to working with WaterburyFarrel and Stiletto Systems Ltd

Team that you can reliably trust to deliver your

ammunition equipment & complete factory

e-mail : kh17@stiletto.uk.comtel. + 44 77 88 437 442

www.stiletto.uk.com

turnkey ammunition plant solution for … · waterbury farrel began shaping the course of history...

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