BAE Systems Revolutionizes UK Munitions with New Explosives and Propellants to Strengthen Defence Supply Chain

BAE Systems has taken a significant step forward in securing the United Kingdom’s defence readiness by developing innovative explosives and propellant technologies. These advancements are designed to strengthen the UK's munitions supply chain, increase self-reliance, and support allied nations in a rapidly changing global security environment.

Since 2022, BAE Systems has invested over £150 million in enhancing its UK-based munitions infrastructure. A key part of this investment is a new state-of-the-art explosive filling facility in Glascoed, South Wales, which is scheduled to become operational this summer. Once active, this facility will enable a remarkable sixteen-fold increase in the production of 155mm artillery shells—essential for modern battlefield operations.

In addition, BAE Systems is committing a further £8.5 million over the next five years to develop next-generation energetics and propellants. These cutting-edge manufacturing methods aim to reduce dependency on traditional materials such as Nitrocellulose and Nitroglycerine, which face global supply constraints. Instead, BAE is introducing a new propellant formulation and employing continuous flow synthesis techniques to produce explosives more efficiently and safely.

One of the most promising outcomes of this research is a successful pilot programme that has proven the ability to produce explosives in smaller, distributed facilities rather than relying on large, centralized explosive plants. This modular approach could significantly reduce investment requirements and enhance flexibility and safety in explosive manufacturing.

Key Features and Specifications:

• Explosive Filling Facility (Glascoed):

  • Sixteen-fold increase in 155mm artillery shell production

  • Supports high-volume defence demands for both UK and allies

  • Fully operational by mid-2025

• New Propellant Formulation:

  • Free from Nitrocellulose and Nitroglycerine

  • Alleviates reliance on limited global raw materials

  • Enhanced safety and reduced environmental impact

• Continuous Flow Synthesis of Explosives:

  • Reduces the amount of explosive material in use at any given time

  • Improves production control and scalability

  • Enables safer and cost-effective production

• Compatibility and Flexibility:

  • Suitable for a wide range of munitions, from small arms to large calibre artillery

  • Designed for integration into both domestic and export defence platforms

• Supply Chain and Economic Impact:

  • Strengthens UK’s defence industrial base

  • Creates high-skilled jobs in Cheshire, Monmouthshire, and Tyne and Wear

  • Opens potential for international defence exports

According to Steve Cardew, Business Development Director at BAE Systems’ Maritime and Land Defence Solutions, "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."

With full-scale production capacity expected by the end of 2026, BAE Systems’ breakthrough in energetics and propellants marks a major leap toward future-proofing the UK's defence needs and supporting global security efforts.