The line has been running since the end of 2025. It takes in sub-components and produces finished, belted rounds without manual intervention. The work is split across three modules: one for cartridge case assembly and filling, one for projectile filling and assembly, and one for final assembly and belting.
“As part of our continued journey towards Industry 4.0, we have successfully implemented advanced automation across complex manufacturing processes, reducing manual labour requirements by nearly 60%,” said Mohammed Arbabi, LAHAB’s chief executive officer. “This enables greater annual output, improved efficiency, and reduced reliance on manual operations, while establishing a stronger foundation for scalable and advanced manufacturing of 40mm grenades.”
Real-time data lets operators fix problems on the line
Production data from all three modules feeds a live dashboard that shows throughput, module performance and production status. Operators can spot deviations and correct them while the line is still running, instead of waiting to go through the figures at the end of a shift.
The line is one of many automation projects across EDGE’s manufacturing businesses. The company says it completed more than 68 Industry 4.0 projects at 28 production facilities in 2025 and doubled capacity at 13 of its entities.
Gains at HALCON and CARACAL
At HALCON, the group’s smart weapons manufacturer, automating assembly of the DESERT STING 16 guided-glide weapon raised production volume by 130% and cut labour content by 23%. The line uses 11 industrial robots, more than 300 sensors and six machine vision stations, along with automated material handling and inspection.
CARACAL, which makes firearms and small-calibre ammunition, brought in automated storage and retrieval. Storage density rose by around 80% and those operations became three times faster. According to EDGE, this meant it no longer had to invest in another warehouse.
The programme is supported by BRIDGE, the group’s innovation, operational excellence and industrialisation function, and more projects are under way across EDGE’s manufacturing base.
