Rifle Gunpowder: Ball vs. Stick

When it comes to reloading rifle ammunition, the first choice to be made is whether to use stick or ball gunpowder. (Handgun ammunition is nearly always ball powder as we generally don't reload for long range pistol accuracy.) What follows is my own opinion, based on my decades of reloading rifle ammunition.

Why Two Kinds?

There are actually more than two kinds of gunpowder shapes, but stick and ball are the most common and effective for reloading. These powders have different burn characteristics due to varying compositions and grain sizes. 

• Stick powder, aka extruded powder, has larger rodlike grains. Think of how a spaghetti noodle is made, but chopped very short. Because of its surface to volume ratio, it needs fewer burn retardants to produce a smooth pressure curve. 
• Ball powder is made up of small, roundish grains whose volume are easily measured. Ball powder has more surface area that stick powder, so to mitigate its faster rate of combustion, powder manufacturers vary the amount of burn retardants to make the powder's pressure curve suit its final application. For an AR-15 this includes a maximum chamber pressure and a maximum and minimum gas port pressure. 

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Cost

When I started reloading decades ago, the cost difference between stick and ball powders for use in rifles was fairly close. However, current market conditions have made ball powders the “economy” option. For instance, an 8 lb jug of Winchester StaBall 6.5 Precision Rifle Smokeless Powder is currently $323 at Powder Valley Outdoors, while stick powder costs hundreds of dollars more: Shooter’s World 4350 costs $510 and IMR 4350 costs $462. This is primarily because of exchange rates and import costs. Ball powders are manufactured in the United States by the St. Marks factory in Florida, as well as around the world, such as Ramshot TAC from Belgium. 

However, stick powders aren’t manufactured in the United States at this time. The IMR line of powders comes from Valleyfield in Canada, and Shooter’s World Powders comes from Lovex in Europe. Other European powder companies include Norma, Vihtavuori, and more, and the Hodgdon Extreme line comes from ADI in Australia. 

This means that prices on stick powders will always fluctuate quite a bit with exchange rates between the Dollar and the Euro or the Australian Dollar, but only some ball powders will feel the impact of exchange rates. Exchange rates aside, the cost increases due to “supply and demand” seems to hit all powders equally. 

Accuracy

While ball powders are generally more cost-effective, stick powders tend to be slightly more accurate. The accuracy improvement isn’t  enough to matter for hunting, but may be just enough to score a few more points at shooting competitions.

For hunting, you want a rifle that will consistently place five shots under two inches at 100, and ball powders can easily achieve this with a standard workup. I know that a two Minutes Of Accuracy rifle and ammo combination sounds pretty lousy here in these days of “Sub-MOA Guarantee!” written right on the box holding your new rifle, but hunting bullets are designed for controlled expansion to provide good terminal performance, whereas match bullets are designed to make nice round holes in paper. In other words, they’re just built differently, so it’s useless to compare their performance. If your rifle can hit two MOA all day long with your hunting load, then you can make a “boiler room shot” on a deer out to 300 yards with confidence. 

Temperature Stability

Stick powders will generally be more temperature stable, meaning they exhibit less velocity shift with ambient temperature changes than ball powders. 6.5 StaBall is advertised as temperature stable, but in testing I found that it had significantly more velocity shift than Hodgdon’s H4350. However, 6.5 StaBall is more temperature stable than Reloader 15, a stick powder used in match ammunition, including M118LR sniper ammunition for the Department of Defense.

Final Recommendations

If you’re just starting in reloading, I recommend beginning with an economical ball powder as it’s easier to use with powder measures to get consistent charges. I’d be very surprised if you didn’t end up with a load that can consistently put five shots under 1.5 MOA after a normal load workup.

The time to spend the money on a premium stick powder is when you start winning competitions and still want to get better, or you’re going on that “hunt of a lifetime” in Africa or Alaska where you want your ammunition to perform more consistently across wild temperature swings.