Hornady is one of the very well known ammunition manufacturers in the US. They are better known for their reloading supplies and presses. What most people don’t know is that if you are in Grand Island, Nebraska you can take a Hornady plant tour for free.
Hornady offers two tours a day Monday-Thursday at 9:30 and 2:30 and one on Friday at 10:30. These tours last a 1/2 hour and show you most of the manufacturing process of making bullets and casings.
History of Hornady
Joyce Hornady started Hornady in 1949 with the idea that people wanted “Accurate, deadly, dependable” bullets they could afford to reload. He had a goal to produce bullets that could he could shoot multiple bullets into the same hole. The first bullets he sold were 150-grain spire point .30 caliber bullets. Which Hornaday still sells today.
Hornady has grown from its start in a repair shop garage to having two plants in Grand Island, Nebraska. They now not only produce bullets, and cases, but they also sell loaded ammunition, along with reloading presses, and equipment. Plus other shooting sports gear, and even some gun safes. They have truly grown to the largest US company for reloading components and equipment. All while still being a family-owned and operated business.
First Impression of Hornady
Like everything I do, I showed up early to the Hornaday plant for the 9:30 tour. Of course, we all know early is on time, on time is late, and late is acceptable. So it didn’t bother me to wait a half-hour for the tour to start. In fact, looking around the lobby of the Hornady plant in itself is pretty cool.
There are plenty of stuffed animal mounts to look at and other trophies and whatnot. All of which gives you the impression that this isn’t your standard manufacturing plant only in it for the money. They really do care about hunting, shooting sports and everything firearms related. Or course the Zombie Ammo Plant set up in the entryway gets your attention but it’s almost overshadowed by all the animal mounts and plaques from firearms competitions.
The Start of the Tour
Our tour guide showed up promptly at 9:30 in a good mood and ready to give a great Hornady Plant tour. You could tell he truly enjoys his job. Although he was pretty amazed that my friend and I had driven as far as we did on one of the foggiest days they’d seen in a long time, just to get a plant tour.
We started the plant tour with the office spaces and conference room. Which we were told is the only place we could take pictures while on the tour. Honestly, this surprised me that we could even take pictures there.
I was more than happy to snap a few pictures of the conference room, and the M1 Garand on the wall. There was some amazing gun collections on the walls in the conference room, and just outside it. Hornady made a deal with Ruger years ago to get one of every firearm the made. So the collection in the conference room is pretty nice. However, these are just a few of the personal firearms collections owned by the Hornaday family. Which do get used every now and then.
The Machine Shop
The first thing we saw as we walked into the plant was their machine shop. To say I was impressed is an understatement. I work for a production company that has a maintenance shop. My companies maintenance shop has always made me jealous that I don’t get to use some of their machines. The Hornaday Plants machine shop made me drool. They have multiple CNC machines and even a few wire EDM machines. Plus what I can only guess was a CMM measuring machine for making sure the tools they create are within spec.
Training and Repairs
The next stop on the tour was their off production machines. Normally this wouldn’t be anything exciting. They are just presses and whatnot that have been taken out of production to be refitted or upgraded. What caught my attention was when the Hornady Plant tour guide explained that while the machines are out off production they use them to train the new hires.
The idea that Hornady is so dedicated to making sure they properly train their employees on how the machines work is impressive to me. Granted I asked the guide when they started this policy and he said pretty recently. They did it because they realized that it gave the new people a chance to learn without fear of slowing production or costing the company extra money. Honestly, I don’t care about the motives. It impressed me they realized trial by fire isn’t the best way to train people.
Lead Processing
The first actual stop on the production floor was the lead processing area. Of course, we didn’t go in as they smelt lead in the room and the operator was wearing a full hazmat suit. However, we got the idea of everything he does. I give this guy full props on doing this job. They get the lead in as bricks and melt it down, process it, and pour it into cylinders for their presses.
Making Lead Cores
From the lead processing, we went to the presses used for making lead wire. This was a cool step. They take the big lead cylinders and press them through a die in a huge press. What comes out is the lead wire they cut down for the lead core of each bullet they make. It was really cool to see just how much lead wire they make and use every day. Plus anything that doesn’t make it through the dies, they melt back down into another lead cylinder.
Bullet Making
Hornady makes all their own bullets for loaded ammunition and reloading in the Grand Island plant. Starting with raw sheet copper, and of course, lead wire. Going all the way through to the complete bullet. They recycle any wasted copper. There really isn’t any waste in the process everything that isn’t used gets melted back down and reused.
There are a few steps to prepare the materials for each bullet, but once the materials are made they all get loaded into big presses. These presses have various dies and multiple stages for forming bullets. The end result is copper jacketed bullets. Each press they have gets set up for a specific type and caliber of bullet. They have lots of presses but not enough to make every caliber and weight of bullet all at once. So these presses get changed around fairly often.
Cases
The shell casings were next on the Hornady plant tour and just like the bullets, it was amazing to see. They had lots of presses taking simple brass cups and turning them into shiny bullet casings. Some cases take lots of steps to press the cups into a full case. Others only took a few steps to make a complete shell casing. Some of the rifle cases where even annealed after being formed. Which unlike when a home re-loader makes an annealing machine. Hornady didn’t use a flame to heat the necks up. They used more of an oven type heating element. It was a pretty cool machine, one I wouldn’t mind having a smaller version of, in my home.
Testing Range
The last stop on our Hornady Plant tour was the testing range. They test bullets from every new run or set up of a machine. This means they have two full-time guys down in a basement room loading bullets into cases to be fired for groups. I seriously wanted to apply for that job right then and there.
The room for loading was pretty much every reloader’s dream. The only thing missing was multiple progressive presses. Which considering the need for accuracy is no surprise. They had every die they could need all neatly organized and ready to put in their single-stage Hornady presses.
The best part of this room is that it’s attached to a 200-meter underground test range. It’s my understanding that Hornady himself used to go “outback” and test all the bullets himself, but he eventually got tired of the wind, rain, and cold. So when they built this plant he put in an underground range. Granted it’s not much more than a cement tube and sled to lock down accuracy barreled actions. It’s still pretty cool. They do have a Barrett .50 BMG sitting the corner for when they need to test .50 caliber bullets.
Option of 2nds and other Hornady Gear
The last stop on the tour is their small gear shop. This is where they sell what is considered 2nds of bullets and some other hats and whatnot. The bullets they sell are the ones made right after they set a machine up for a new run. Honestly, I can’t see anything wrong with them. However, Hornady has very high standards for quality and they want to make sure every bullet they sell is perfect.
Conclusion
The Hornady Plant tour is one of the best tours I’ve ever been on. Honestly, after having gone on the tour I’d say it would be worth paying for. The great thing is you don’t have to. It’s a free tour. Though you will have to drive to Grand Island, Nebraska to take the tour, even the time and fuel cost is worth it. For anyone who likes firearms, or reloading this is a great way to spend an hour of your time.