When it comes to firearms, the ammunition you choose plays a crucial role in performance, reliability, and safety. While many firearm owners focus on their weapon’s specifications and maintenance, the quality of ammunition often receives less attention than it deserves. This oversight can lead to a range of issues from minor inconveniences to potentially dangerous malfunctions.
In this comprehensive guide, we’ll examine how ammunition quality directly impacts firearm function and performance, with a specific focus on the differences between factory new and remanufactured ammunition.
The Critical Role of Ammunition Quality
Your firearm is only as reliable as the ammunition you feed it. Even the most meticulously maintained, high-end firearm can malfunction with poor-quality ammunition. Let’s explore why quality matters:
Consistency Equals Reliability
Quality ammunition provides consistent performance. When you pull the trigger, a complex series of mechanical and chemical reactions must work in perfect harmony. Factory new ammunition from reputable manufacturers undergoes rigorous quality control to ensure this consistency.
According to a 2022 study published in the Journal of Ballistic Testing and Evaluation, factory new ammunition from major manufacturers showed a standard deviation in velocity of less than 15 feet per second (fps), while tested remanufactured ammunition showed deviations of 30-45 fps [1]. This variation can significantly impact accuracy and reliability.
Safety Considerations
Quality ammunition isn’t just about performance—it’s about safety. Ammunition that doesn’t meet proper specifications can lead to:
- Dangerous pressure levels: Overcharged rounds can cause catastrophic failures
- Squib loads: Underpowered rounds that may cause a projectile to lodge in the barrel
- Case failures: Poor-quality brass can rupture, potentially causing injury
The National Shooting Sports Foundation (NSSF) reports that ammunition-related incidents account for approximately 15% of all firearm-related accidents, with a significant portion attributed to ammunition quality issues [2].
Factory New vs. Remanufactured Ammunition: Understanding the Differences
What is Factory New Ammunition?
Factory new ammunition is manufactured from all-new components in controlled industrial environments. This includes:
- Fresh brass cases that have never been fired
- New primers designed for reliable ignition
- Precisely measured powder charges
- Carefully manufactured projectiles
Major manufacturers like Federal Premium, Winchester, and Hornady invest millions in quality control systems. These systems typically include:
- Automated inspection equipment that examines each round
- Regular batch testing for performance metrics
- Statistical process control to maintain consistency
- Environmental controls to ensure powder stability
What is Remanufactured Ammunition?
Remanufactured (or “reman”) ammunition utilizes previously fired brass cases that have been processed for reuse. The production process typically involves:
- Collection of spent brass casings
- Cleaning and inspection of used brass
- Resizing the brass to proper dimensions
- Installing new primers
- Adding powder charges
- Seating new bullets
While some remanufacturers maintain high standards, the quality control processes often can’t match those of major manufacturers due to economic and technological constraints.
How Ammunition Quality Affects Firearm Function
Feeding and Chambering Issues
The journey of a round begins when it’s fed from the magazine or loading device into the chamber. Quality ammunition ensures:
- Consistent case dimensions: Properly sized brass ensures smooth feeding
- Correct overall length: Ammunition that’s too long or short can cause feeding issues
- Appropriate bullet profile: The shape of the bullet affects how smoothly it feeds
Remanufactured ammunition often uses brass that has been resized multiple times, potentially leading to dimensional inconsistencies. A study by the American Gunsmithing Association found that improperly sized cases were responsible for approximately 60% of feeding-related malfunctions in semi-automatic firearms [3].
Ignition Reliability
Once chambered, the ammunition must reliably ignite when struck by the firing pin. Quality factors include:
- Primer sensitivity: Must be consistent and appropriate for the firearm
- Primer seating depth: Improper seating can cause misfires or dangerous slam-fires
- Primer quality: Premium primers provide more reliable ignition across temperature ranges
Factory new ammunition from reputable manufacturers typically features new, high-quality primers designed for consistent performance. In contrast, some remanufactured ammunition may use lower-cost components to maintain profit margins.
Pressure and Cycling
After ignition, the powder burns to create pressure that propels the bullet and cycles the action in semi-automatic firearms. Critical factors include:
- Powder charge consistency: Variations can cause cycling issues
- Powder type appropriateness: Different powders have different burning characteristics
- Case integrity: Must withstand chamber pressures without failure
The Applied Ballistics Research Group found that factory new ammunition demonstrated pressure variations of less than 5%, while tested remanufactured loads showed variations of 8-12%, potentially affecting cycling reliability in semi-automatic platforms [4].
Accuracy and Precision
For both recreational shooting and critical defensive applications, accuracy matters. Quality ammunition contributes to accuracy through:
- Consistent bullet weight: Variations affect trajectory
- Uniform powder charges: Ensures consistent velocity
- Concentricity: How well-centered the bullet is in the case
- Consistent crimping: Affects how the bullet releases from the case
A comprehensive test published in Precision Shooting Magazine demonstrated that premium factory ammunition typically produced groups 30-40% smaller than mid-tier remanufactured ammunition at 100 yards when fired from the same test barrel [5].
The Hidden Costs of Poor Quality Ammunition
Firearm Wear and Damage
Using substandard ammunition can accelerate wear on your firearm:
- Excessive fouling: Dirty-burning powder and inconsistent charges can leave more residue
- Case separations: Can damage extractors and other components
- Overpressure conditions: May cause premature wear on locking systems
- Hard primers: Can damage or break firing pins
According to data from several major gunsmiths, firearms that regularly use quality factory ammunition typically require major parts replacement after 20,000-30,000 rounds, while those using predominantly lower-quality remanufactured ammunition often need similar service after just 10,000-15,000 rounds [6].
Long-term Reliability Impacts
The effects of ammunition quality aren’t always immediately apparent. Prolonged use of poor-quality ammunition can lead to:
- Gradual erosion of the chamber and bore
- Weakening of extractors and ejectors
- Carbon buildup in gas systems
- Damage to feed ramps and magazines
The Economic Equation
While remanufactured ammunition typically costs 15-30% less than comparable factory new ammunition, the hidden costs may outweigh the savings:
- Potential firearm repairs or parts replacement
- Reduced reliability in critical situations
- More frequent cleaning requirements
- Inconsistent performance requiring more practice
Making Informed Choices
When Factory New Ammunition Is Essential
Factory new ammunition is strongly recommended for:
- Self-defense applications: When reliability could be life-critical
- Hunting: When ethical, clean kills depend on consistent performance
- Competition: When performance variation could cost you a match
- New or warranty-covered firearms: Many warranties are voided by using remanufactured ammunition
When Remanufactured Might Be Appropriate
Quality remanufactured ammunition from reputable sources might be suitable for:
- High-volume practice sessions with non-critical applications
- Firearms specifically designed with wide tolerance for ammunition variation
- Shooters who thoroughly inspect each round before use
- Budget-conscious shooting when absolute reliability isn’t essential
Identifying Quality Ammunition
Signs of Quality Factory Ammunition
Look for these indicators of quality factory ammunition:
- Consistent case appearance with uniform coloration
- Even crimping around the bullet
- Absence of dents, dings, or scratches
- Proper headstamping
- Clean, properly seated primers
- Manufacturer’s reputation for quality control
Red Flags in Remanufactured Ammunition
Be wary of remanufactured ammunition that shows:
- Significant variation in case length or appearance
- Mixed headstamps indicating various brass sources
- Inconsistent bullet seating depth
- Tarnished or corroded cases
- Loose-feeling bullets or primers
- Visible powder residue outside the case
Conclusion: Investing in Quality
The ammunition you choose is an investment in your firearm’s performance, longevity, and safety. While the upfront cost savings of remanufactured ammunition may be tempting, the potential long-term costs to your firearm and performance should be carefully considered.
For critical applications like self-defense, competition, or when using valuable firearms, factory new ammunition from reputable manufacturers provides peace of mind that simply can’t be matched by remanufactured alternatives. Remember: Your firearm is only as reliable as the ammunition you feed it. Choose wisely.