Eric - Could you explain, in general terms, the procedure for specifying the lot number on these new bullets?
Does a particular lot of jackets always stay together through all of the assembly procedures?
Assuming there is more than one machine, is each assembly machine segregated to produce it's own lot number?
Are there any plans to use this technology for .22's or other calibers?
Any plans for a 500 count box?
The lot number is simply our internal job order number. These numbers are sequential. For those who aren't familiar with manufacturing, when we need to make bullets we issue what is called a job order. This document specifies all the particulars for that run. This document follows the job through the entire process. When the bullets are finished we list the job order number as the lot number. As of today (7-27-12) we are over 4,600 job orders issued (this number has gone back to zero a few times in the last several years for various reasons). So anything with a lot 4637 or smaller was made before today. Any higher lot number will be made in the future. I hope that's clear.
We use very strict lot controls. When we receive copper, the lots are recorded and the copper is clearly labeled. We can use only one lot of copper to make one lot of jackets. If the copper lot changes we change the lot number of the jackets even if the tooling and set up is exactly the same. When the jackets are pulled to make bullets we can use only one lot of jackets for each job order (lot). If we need to make 100,000 bullets but we have one lot of jackets that is 35,000 and another that is 65,000 our need for 100,000 will be split into two different job orders (lots) and run separately. When jacket lots get mixed they end up in the scrap bin. I really don't like it when this happens. It doesn't happen often. We will never use more than one lot of jackets for any lot of bullets.
Each job order (lot) runs on only one machine. Since we designate one die for each bullet we can't run the same bullet on two machines even if we thought it was a good idea, which we don't. We have strict controls over how the bullets are collected, cleaned and processed through packing. This rarely produces an issue since most of the time we are running bullets that are visually very different from each other. It is hard to mix 6mm 68 gr with 30 cal 230 gr for example.
We do have plans to apply Bryan's design to both the 22 cal and 30 cal BR bullets. Keep in mind that the same process is required (thorough testing of several designs and lead column heights) so it will be a while before these bullets are available. The various 6mm BR Column designs that were tested took four years to resolve and Bryan has not designed the 22 cal and 30 cal options yet.
At this time we don't have plans for a 500 count box. I can't stress strongly enough that the bullets in one 100 count box, 5 - 100 count boxes and 1 - 1,000 count box are exactly the same in every way within a specific lot. These lot numbers are clearly marked on each box. From a performance point of view there are no gains to buying them in 100 count boxes or 1,000 count boxes. Having said that, I've been around BR long enough to know that the mind of a BR shooter is an active and fickle thing. BR shooters don't tend to believe much that is said until it is proven in their gun so for that reason we have the 1,000 count box available. If someone told me that this made a difference in their gun I will appreciate it very much if they could explain why because I can't.
Regards,
Eric