Recently, Brad Johnson and Matt Williamson from NIOA had the opportunity to explore the heart of this iconic brand during their visit to the Federal Ammunition Factory in Anoka, Minnesota. Guided by David Leis, International Vice President of Sales at Federal, the tour provided an in-depth look at the processes that underpin Federal’s reputation for high-quality ammunition.

This philosophy is central to Federal’s operations, where meticulous attention to detail is evident at every stage of production.

“Being based in America allows us to control the process and ensure a higher quality product by knowing the components that go into our ammunition,” Leis explained.

The Anoka facility, where temperatures can plunge to a frigid -20°C, is a testament to the company’s rigorous standards. Here, lead sourced from recycled car batteries is transformed into wire, which is then used to create bullet cores, rimfire bullets, or BBs for shotshells. The factory is divided into specialised sections - rimfire, centrefire rifle, pistol and shotshell.

In the centrefire section, Brad and Matt observed the intricate process of cartridge loading. The journey from lead cores to finished bullets involves placing primers into cartridge cases and assembling all components into the final loaded cartridges. Federal’s product range is extensive, offering over 300 SKUs, including the popular Power-Shok line for entry-level hunting ammunition and the Fusion line, which represents a step up in quality.

Federal’s history is as storied as its products. In 1916, the Sherman Brothers founded the Federal Cartridge and Machine Shop, but their venture was short-lived. It wasn’t until 1922, when Minneapolis businessman Charles Horn recognised the factory’s potential, that the Federal Cartridge Corporation was officially established. Horn’s unconventional approach to distribution - selling ammunition in barber shops, hardware stores and gas stations - laid the foundation for Federal’s eventual success.

The 1970s marked a turning point for Federal with the introduction of the premium ammunition category in 1977. This bold move, which involved producing higher-cost ammunition, proved to be a success and has since become a cornerstone of the Federal brand.

The visit also included a tour of Federal’s Custom Shop, where attention to detail is paramount. This facility is divided into two sides: shotshell and centrefire. On the centrefire side, brass is meticulously sorted, prepped and loaded with the best components and powders available. The ammunition is then polished, packed and custom labelled after a final inspection. The shotshell side specialises in waterfowl and turkey loads with each load tailored to specific requirements.

The workers at Federal, many of whom are passionate members of the shooting and hunting communities, take immense pride in their work. “Made in America, Federal Ammunition is known for its quality and craftsmanship, which is highly valued by consumers and shooters alike,” Leis stated, underscoring the brand’s commitment to excellence.

Australia is a key market for Federal and the company’s long-standing partnership with NIOA, spanning over 20 years, has been instrumental in meeting the growing demand. The consistent growth in sales has enabled Federal to ship a container of ammunition to Australia once a month, ensuring a reliable supply chain as the market continues to expand.

The COVID-19 pandemic presented challenges, particularly with the heightened demand for primers from military and law enforcement agencies. Despite a temporary shortage, Federal has ramped up production and begun shipping more primers in the past six months, with the supply expected to improve further in 2024.

Brad and Matt learned a lot about the intricate processes involved in ammunition and primer manufacturing during their visit. “It was incredible to witness the level of craftsmanship and precision that goes into producing loaded ammunition,” Brad remarked.

Matt was equally impressed, noting, “Federal’s commitment to quality is evident across their entire range. Whether it’s the budget-friendly Power-Shok or their premium ammunition, customers can trust that they’re receiving quality and performance every time.”

After their Federal Factory tour in Minnesota, Brad and Matt headed to the warmer climate of Oroville, California, where they visited RCBS, another key player in the shooting and reloading industry.