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.