BAE Systems Advances Explosives and Propellants Production to Boost UK Defence Resilience

BAE Systems Advances Explosives and Propellants Production to Boost UK Defence Resilience

(IN BRIEF) BAE Systems has made significant strides in the development of novel energetics and propellants, following £150 million of investment since 2022 to increase UK munitions manufacturing. A newly developed continuous flow processing technique will reduce dependence on globally scarce materials like Nitrocellulose and Nitroglycerine, enabling safer, more efficient production of explosives and propellants. The company expects to meet UK and export demands from 2026 onwards. These innovations will enhance national security, improve manufacturing safety, and support job creation, as part of BAE Systems’ broader commitment to strengthening defence capabilities.

(PRESS RELEASE) FARNBOROUGH, 22-Apr-2025 — /EuropaWire/ — BAE Systems has unveiled pioneering new manufacturing techniques for explosives and propellants, aiming to reinforce the UK’s defence supply chain and boost the nation’s munitions self-sufficiency. This milestone builds upon more than £150 million invested by the company since 2022 into its UK munitions infrastructure, which includes a major expansion of its 155mm artillery shell production at Glascoed, South Wales. The upgraded explosive filling facility, set to open this summer, will deliver a sixteen-fold capacity increase.

In parallel, BAE Systems has committed an additional £8.5 million over the past five years to innovative manufacturing R&D, resulting in significant advancements in creating next-generation energetics. Among the breakthroughs is the adoption of continuous flow processing for synthesising explosive materials, eliminating reliance on traditional, globally scarce ingredients such as Nitrocellulose and Nitroglycerine in the production of propellants.

These technological innovations are poised to enable domestic production to meet both UK Ministry of Defence needs and international export demands, with the first phase of industrial-scale output targeted by late 2026.

“Our breakthrough in synthetic energetics and propellant production is a crucial step toward strengthening the UK’s defence readiness and scaling up vital munitions output,” said Steve Cardew, Business Development Director at BAE Systems’ Maritime and Land Defence Solutions. “It’s not just about security—it’s also about stimulating the economy through skilled jobs and new export avenues.”

The company has successfully piloted the novel explosive synthesis method, producing materials in modular nodes rather than relying on large-scale factory setups. This approach dramatically reduces infrastructure requirements while increasing safety through continuous-flow manufacturing, which keeps the quantity of explosive material being handled at any time to a minimum.

The new propellant formulations have already been tested across multiple ammunition types, from small arms to large-calibre rounds. With this new manufacturing model, BAE Systems expects lower operational costs, greater efficiency, and a safer working environment.

As the UK Ministry of Defence’s primary ammunition supplier, BAE Systems operates across key sites in Cheshire, Monmouthshire, and Tyne and Wear, producing a wide range of munitions including small arms and artillery shells.

Media contact:
Andrew McDowell
Head of Media UK – BAE Systems
+44 (0) 7801 717739

Erin Askew
Communications Manager, BAE Systems Maritime and Land Defence Solutions
Mobile: +44 (0) 3300 488470

SOURCE: BAE Systems