Astor Defence

Henry Turnbull, Head of Military Packaging

The organisation traces its roots to an era when the Royal Ordnance Factories were the backbone of British military manufacturing. Producing weapons and military equipment, these government-owned facilities were integral in arming the nation. Amidst a sweeping wave of privatisation in the late 20th century, they became part of British Aerospace, now known as BAE Systems, marking a significant transformation in operational focus.

As new manufacturing technologies emerged, Astor Defence found itself at a crossroads.

“As the defence industry evolved, we realised that our true potential lay in leveraging our deep-rooted knowledge of military needs to specialise in packaging rather than production of ammunition components,” explains Henry Turnbull, visionary Head of Military Packaging at Astor Defence.

This resilience resulted in securing its first Ministry of Defence Procurement Data Standard (PDS) contract in the 1980s for ammunition packaging design and production, marking a new chapter for the company.

Today, Astor Defence is recognised as the sole source supplier of metal ammunition containers for the British Army, a testament to its enduring commitment and excellence. Its expertise extends beyond the UK, providing services for armed forces in the NATO alliance, including France, Germany and Italy. This broad acceptance of its high-calibre packaging solutions across Europe highlights its critical role in military logistics while underscoring its prominence in the defence sector.

Comprehensive Ammunition Packaging Solutions

Astor Defence offers a diverse range of metal packaging solutions. Its product lineup includes small calibre ammunition cans, notably the M19A1, M2A1 and M2A2 models, designed for ammunition up to 12.7 millimetres.

Expanding its reach, Astor Defence also caters to medium-and large-calibre ammunition, with equal proficiency. For medium-calibre options, its robust containers accommodate 20mm, 25mm, 30mm and 40mm ammunition, complete with all-metal enclosures enhanced with foam, cardboard or timber inserts customised to fit securely inside each can.

Its capabilities extend to larger calibres, mainly 120mm tank ammunition and 60,81 and 120mm mortar ammunition, for which it make specialised containers, such as the PA116, the PA171, the PA191, the PA156 and the PA154 all tailored for insensitive munitions. This level of specialisation includes internal mortar packaging, which uses spiral wound fibre tubes to securely hold 60mm to 120mm rounds within durable metal cases.

Each product undergoes rigorous testing protocols to assure reliability and optimal performance, adhering to rigorous military specifications, from dimensional checks and corrosion testing to weld inspections and temperature resilience evaluations. These tests certify that Astor’s packaging solutions not only meet but often exceed the highest standards of durability and operational excellence.

Expanding Frontiers: Strategic U.S. Market Penetration

As the company grew, so did its ambitions. It identified a big opportunity in the lucrative U.S. market, where domestic suppliers struggled with quality and lead times. Offering a superior alternative, it quickly partnered with major U.S. munitions manufacturers, like Northrop Grumman, Day and Zimmerman and General Dynamics, which extensively use Astor’s advanced packaging solutions.

A pivotal development was forging direct relationships with the U.S. government, marking a shift from its traditional approach of supplying through prime contractors.

“We are now directly collaborating with the U.S. Army, which has begun conducting tests at our UK facilities,” says Henry.

The direct engagement allowed it to align closely with the U.S. Army’s requirements, signifying earned trust from one of the world’s most formidable powers.

Rigorous testing processes ensure compliance with U.S. government standards. When awarded a U.S. government contract, manufacturers must conduct First Article Acceptance Tests that include various on-site audits by U.S. government representatives. The testing regimen involves extensive destructive testing to determine durability and resilience. In corrosion testing, containers are subjected to harsh conditions for up to 400 hours. Welds are also tested, as is the ability of containers to withstand high temperatures. Tests also ensure that the packaging meets all U.S. Army specifications, including checks for dimensional accuracy to ensure the packaging meets military requirements.

The company host representatives from the U.S. at its UK facility to conduct and observe an initial audit. This led to the successful qualification of its containers for a 60mm mortar contract. Astor was the sole supplier capable of meeting the short lead time required on this contract which demonstrates its ability and its potential to reduce costs and lead times for its clients. It is also due to host representatives from the US Army to observe further FAATs, which will lead to further orders.

The successful audit also resulted in Astor receiving a contract for 81mm mortar containers. It is furthermore setting its sights on larger projects, including a potential deal to produce containers for 120mm tank ammunition. These initiatives could redefine industry standards and highlight Astor’s role in shaping global defence logistics.

A commitment to technological advancement is evident in its recent investments to enhance operational efficiencies. The introduction of a high-speed industrial inkjet printer has revolutionised its labelling process, increasing throughput to 250 containers per hour and significantly reducing bottlenecks. The implementation of the state of the art, fully automated zinc phosphate line, unique in the market, exemplifies its dedication to quality. The line ensures that every container exceeds durability standards required by military specifications, setting Astor Defence apart from its competitors.
Quality assurance is a cornerstone of its operations. While others subcontract outsource testing, Astor conducts it at its in-house laboratory. Advanced equipment, including vacuum chambers, chemical composition analysis machines and tensile weld test machines are used. In-house capability gives it greater control over the production process and quicker response times to issues.

Astor Defence has distinguished itself by not just meeting but anticipating client needs, offering customised solutions that enhance its product’s functionality and application.

“We’re not just about meeting specs; we’re about creating solutions,” Henry asserts.

One notable success story illustrates the firm’s adaptability. An IT sector client was aware that Astor’s military containers could be repurposed to secure sensitive electronic equipment. Although the details are under NDA, Astor modified one of its ammunition containers to meet their specific needs, reinforcing it to withstand increased pressure and adding various threaded fittings for sensors and monitoring devices.

Ensuring Flexibility and Rapid Response

In an industry fraught with challenges, Astor has consistently demonstrated resilience and adaptability. The fluctuating cost of raw materials and the complexities of global shipping are significant hurdles. These concerns are addressed through strategic stock management and long-term supply agreements.

A robust inventory of 30,000 to 40,000 boxes is maintained to allow for immediate deployment. This strategy is particularly vital given the nature of global events that demand a quick response. Many clients, often at the final stages of production, realise the necessity for high-quality packaging. Astor’s readiness ensures that these pressing demands are quickly met, maintaining the flow of military logistics even under tight deadlines.
Setting New Industry Benchmarks

Astor Defence is poised for further growth and expansion. Its recent, successful and growing relationship with the U.S. Army marks the beginning of a chapter, and there are plans to secure additional contracts for small-calibre, medium-calibre and large tank ammunition packaging. It intends to strengthen its position as a leader in ammunition packaging and explore new opportunities in related industries.

The story of Astor Defence is one of continuous evolution and a relentless pursuit of excellence. It has consistently adapted to meet its client’s changing needs to establish itself as a trusted supplier to many of the world’s largest defence contractors. Under Henry Turnbull’s leadership, Astor Defence remains committed to innovation, quality and customer satisfaction. As they look ahead, its dedication to these core principles ensures they will continue to play a vital role in the global defence supply chain.