Ammunition Factory

Project idea

AMMUNITION FACTORY
The ammunition factory in Skenderaj has a long and important history for the region. Built around 70 years ago, it was part of the former Yugoslavia's military industry and played a key role in the production of ammunition, especially for hunting rifles. After the end of the war in Kosovo, the factory was abandoned and remained out of operation, turning into a dilapidated and unused facility. The factory was part of the Trepça complex, one of Kosovo's most important industrial assets. However, it was not involved in the privatisation process by the Privatisation Agency of Kosovo (KPA), as its location was considered part of the Adem Jashari Memorial Complex. This complex has a special historical and national importance, influencing decisions about the future of the factory. In recent years, there have been discussions about re-functionalizing the plant, but these efforts have faced numerous challenges, including a lack of investment and other national priorities. Its re-functionalization would require an in-depth analysis of the region's economic and social needs, as well as a clear plan to ensure that the factory contributes to the sustainable development of the community.

FUNCTIONALIZATION
The functionalization of the ammunition factory in Skenderaj could bring significant benefits to the region and beyond: 1. Employment and economic development: The opening of the factory would create job opportunities for local residents, helping to reduce unemployment and improve the standard of living in the area. 2. Historical and military heritage: The factory could serve as a symbol of the continuity of military tradition and efforts for the construction of the state of Kosovo, respecting the history and contributions of the region. 3. Utilization of existing spaces: The spaces of the former factory are large and underutilized, providing opportunities for the development of a modern complex without negatively impacting the surrounding area. 4. Improvement of national security and capabilities: An ammunition factory would contribute to strengthening the military and security capabilities of Kosovo, reducing reliance on imports. 5. Positive impact on the community: In addition to employment, the factory could help in training and developing the skills of local workers, contributing to the sustainable development of the region.

Project description

DESCRIPTION OF THE IDEAL PROJECT OF THE FACTORY
The modern ammunition factory is built to meet the highest standards of technology and safety, integrating advanced processes for the production of ammunition in various calibers. With an area more than 6000 square meters, it accommodates around 200 workers and provides an efficient and organized working environment. The production capacity includes ammunition for small arms such as 9mm, .45 ACP, .223 Remington, and 7.62x39mm, as well as ammunition for shotguns in calibers such as 12-gauge and 20-gauge. Additionally, the factory produces special high-precision ammunition, covering a wide range of needs. One of the key components is the line for producing bullets and shells, equipped with modern technology such as presses for lead cores and furnaces for the heating process, which ensure high-quality and standardized products. The spatial structure includes all the necessary elements for advanced and safe operation, positioning itself as a reference point in ammunition production.

Technical information

TECHNOLOGICAL PROCESS
The technological process of lead production in the ammunition factory begins with the collection of lead material which is extracted from the TREPÇA mines, and transported by truck to the ammunition factory in Skenderaj, where it is stored in raw material warehouses. After this, the melting of lead begins, where the raw material is transformed into usable material through special furnaces. After melting, the material is stored in dedicated warehouses, adhering to safety standards. The melted lead is processed in the bullet manufacturing halls to create the necessary components for cartridge production. At the same time, the shells and plastic mechanisms are produced with specialized equipment, ensuring durability and technical accuracy. The filling of cartridges with gunpowder takes place in controlled environments, respecting safety and efficiency standards. The process moves to the final assembly halls, where components are joined to create the final product, which is then subjected to careful quality inspection. After inspection, the cartridges are packaged and prepared for transport. This technological process ensures the integration of each phase efficiently and safely, providing a high-quality final product.

-------------------------------------------------------------PROJECT IDEAL PRODUCTION AREA (1000-1200 m²)---------------------------------------------------------------------
-LEAD MELTING (300 - 350 m2) - 4 machines Required area per machine, about 75 m2 per machine
-LEAD PROCESSING (100 - 150 m2) - 4 machines Required area per machine, about 36 m2 per machine
-LEAD COATING (80 - 120 m2) - 4 machines Required area per machine, about 16 m2
-STEEL TIP SETTING (90 - 120 m2) - 2 machines Required area per machine, about 48 m2
-CAPSULE TRIMMING (120 - 160 m2) - 4 machines Required area per machine, about 28 m2
-INITIAL FORMING OF CAPSULES (180 - 220 m2) - 9 machines Required area per machine, about 18 m2 Required area per machine, about 12 m2
-FINAL FORMING OF CAPSULES (100 - 120 m2) - 8 machines
-REINFORCING THE CAPSULE NECK (80 - 100 m2) - 6 machines Required area per machine, about 12 m2
-FINAL REINFORCEMENT OF CAPSULES (130 - 160 m2) - 2 machines Required area per machine, about 64 m2 Required area per machine, about 20 m2
-CAPSULE CLEANING (120 - 140 m2) - 6 machines PRIMER SETTING (50 - 80 m2) - 4 machines Required area per machine, about 12 m2
-FINAL ASSEMBLY - Small caliber - (70 - 100 m2) - 3 machines Required area per machine, about 24 m2
-FINAL ASSEMBLY - Large caliber - (80 - 100 m2) - 3 machines Required area per machine, about 36 m2
-CAPSULE INSPECTION (40 - 60 m2) - 4 machines Required area per machine, about 10 m2
-FINAL INSPECTION (60 - 80 m2) - 4 machines Required area per machine, about 13 m2
-VISUAL INSPECTION (60 - 80 m2) - 4 machines Required area per machine, about 13 m2
-SHELL CONNECTION - for some of the calibers - (60 - 80 m2) - 2 machines Required area per machine, about 28 m2
-PACKAGING (100 - 140 m2) - 4 machines Required area per machine, about 23 m2

-----------------------------------------------------------------STORAGE FOR RAW MATERIALS (150-200 m²)--------------------------------------------------------------------------
Storage space for lead, copper, and bronze.
Euro Pallet: Each has dimensions of 0.8 m x 1.2 m = 0.96 m² and can hold up to 1 ton. For 10 tons, 10 pallets are needed.
Passage space: For a forklift with fixed forks, about 2.75 m is needed for maneuvering.
Required space: 10 pallets occupy 9.6 m² just for their base.
With shelves for two rows and a central corridor, the area includes: Total width: Two rows of 2.5 m + corridor of 3.45 m = 5.95 m Total length: Row with 6 pallets = 7 m Total area of one depot: 5.95 m × 7 m ≈ 45 m²
Total overall area: 45 × 3 = 135 m² Height of shelves: Can be optimized up to 6 m, saving floor space.
Total storage space: About 30-40 m² to store 10 tons and ensure forklift maneuvering.

------------------------------------------------------------------------Space for storing gunpowder-----------------------------------------------------------------------------------------
To produce 75,000 cartridges per day at 5g per cartridge - 5*75000(cartridges per day) = 375000g = 375 kg, for a period of 30 days, around 12 tons of gunpowder are required.
This calculation is based on an average amount of 0.3 to 0.5 grams of gunpowder per cartridge.
A 200-liter barrel can hold about 150 kg of gunpowder (due to density and safety space).
For 12 tons, approximately 80 barrels will be needed. Each pallet can usually hold 4 barrels.
This means about 20 pallets will be needed. Each pallet occupies an area of 1.2 square meters.
For 20 pallets, the total space required is about 24 square meters, just for their base.
The space for maneuvering a forklift is about 2.75m.
With shelves for two rows and a central aisle, the area includes: Total width: Two rows 2.5 m + aisle 3.45 m = 5.95 m
Total length: Row with 10 pallets = 12 m Total area: 5.95 m × 12 m ≈ 72 m²
• Includes security and ventilation systems.

ADMINISTRATIVE PART (300-400 m²)
• Proposed offices: o General Manager: 35 m².
o Technologist: 25 m².
o Secretary: 12 m².
o Engineer: 20 m².
o Technological preparation of production: 20 m².
o Accounting: 20 m².

LOCKER ROOMS AND BATHROOMS FOR WORKERS (180 m² for each category)
• For females: o 100 lockers for clean clothes with a total area of 50 m².
o 100 lockers for dirty clothes with a total area of 50 m².
o Bathroom with an area of 30-40 m².
o Washroom for 100: around 30–40 m² • For males:
o 100 lockers for clean clothes with a total area of 50 m².
o 100 lockers for dirty clothes with a total area of 50 m².
o Bathroom with an area of 40-50 m².
o Washroom for 100: around 40–50 m².

CANTEEN AND KITCHEN (300-400m²)
• CANTEEN
Seating area: Each occupied seat takes between 1.0 and 1.2 m².
Taking an average of 1.1 m² per seat, for 100 people: 100×1.1 m²=110 m²
Circulation area and additional spaces: Corridors for circulation and the self-service system increase the area to nearly double that.
Total area of the canteen: ≈200 m²

KITCHEN
Functional kitchen for the self-service system.
Capacity for 200 seats.
Base area: Approximately 0.30–0.35 m² per served food.
Taking the average value of 0.33 m² for 200 foods: 200×0.35 m²≈70 m²
Additional spaces for movement and storage: 60m² In total: Kitchen≈140m²

AMBULANCE
• Admission
• Waiting
• Ward (4 beds)
• Nurse station • Sanitary

FINAL PRODUCT DEPOT (250-300 m²)
• Space for storing finished ammunition with a capacity of 3,000,000 Cartridges. After production, the cartridges are packed into specialized boxes. Typically, each box contains about 500 cartridges. The box is designed to ensure that the ammunition remains secured, with a strong locking system that prevents unauthorized opening and package loss during transport.
-For 3,000,000 bullets:
-Number of boxes: 6,000 (500 bullets per box)
-Number of pallets: 150 (40 boxes per pallet)
-Area without additional space: 180 m² (150 pallets × 1.2 m²)
-Total area with additional space: approximately 280 m²

ASSISTANCE AREAS (200-300 m²)
• Includes: o Boiler/heating: 100 m².
o Transformer station: 20 m².
o Maintenance workshops: 40 m².
o Space for vehicle servicing and washing: 200 m².
o Polygon: 350 m².

SECURITY AND CONTROL AREA (40 m²)
o Space for security and WC.
o Entrance with full control.

SHOWROOM AND SALES CENTER (100-250 m²)
• Space for product display and client meetings.

PARKING AND INFRASTRUCTURE FOR EMPLOYEES
• Parking for bicycles and vehicles.
• Sports field for recreation.

Documentation

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