How are Paintballs made

How are paintballs made?

There is a bit more to making paintballs than you would first think. It’s easier to make a paintball gun than to make a paintball. This was something the first manufacturers of paintball guns came to find out quite quickly. They made the gun, but how on earth do you make the paintballs? So next time you play paintball, think back to this article and appreciate the work that went into the ball you are just about to fire at your mate.

So the simple explanation. Two sides of a paintball are stuck together and filled with paint. If you want to know everything about the process, read on, but be warned. If you get to the bottom of this post, you will know everything there is to know about how a paintball is made.

The Anatomy of a Paintball

parts of a paintball

A paintball consists of two main components: the outer shell and the inner paint fill. The outer shell is a thin, semi-flexible layer made from gelatine or a biodegradable polymer. The shell is designed to rupture upon impact, releasing the paint inside. The inner paint fill is a water-soluble, non-toxic, and biodegradable mixture of ingredients, including water, polyethelene glycol, dye, and other additives. This paint mixture is designed to be easily visible and washable, without causing harm to the environment.

Preparing the Paint

The first step in making paintballs is preparing the paint mixture. Manufacturers use a combination of water, polyethylene glycol, and dye to create vibrant colours that make paintball an engaging visual experience. The specific formula for the paint varies depending on the desired colour, consistency, and performance characteristics.


Polyethylene Glycol
  • Water: The primary ingredient in paintball fill, water acts as a solvent for the other ingredients.
  • Polyethylene glycol: A water-soluble polymer, polyethylene glycol is a binding agent and thickener, providing the paint with the right consistency.
  • Dye: Dyes are used to create the vibrant colours that make paintballs visible upon impact. They must be bright, visible, and easy to wash off clothing and gear.
  • Other additives: Manufacturers may include additional ingredients to improve the performance of the paint, such as preservatives to extend shelf life, thickeners to adjust consistency, and surfactants to enhance the paint’s ability to spread upon impact.

Mixing and Quality Control

The ingredients are carefully measured and mixed to achieve a uniform and consistent paint mixture. Quality control measures are essential at this stage, as any variation in the paint’s properties can significantly affect its performance. Manufacturers will test samples from each batch for colour consistency, viscosity, and other vital factors to ensure the paint meets the desired specifications.

Manufacturing the Shell


The outer shell of a paintball is critical to its performance, as it must be strong enough to withstand storage and handling, yet brittle enough to break upon impact. The shell is typically made from gelatine, a protein derived from animal collagen, or a biodegradable polymer. The choice of material depends on factors such as cost, environmental impact, and desired performance characteristics.

Gelatine Shells

Gelatine shells are made using a process called encapsulation. The process begins with mixing gelatine powder with water, glycerine, and other additives to create a liquid gelatine solution. The solution is then heated to dissolve the gelatine and ensure a consistent mixture.

Polymer Shells

Polymer shells are an alternative to traditional gelatine shells, offering increased durability and a more environmentally friendly option. These shells are made using injection moulding, a process in which the polymer material is melted and injected into a mould under high pressure.

How are Paintballs made? – The Encapsulation Process

The encapsulation process begins once the paint mixture and shell materials are prepared. This process involves depositing precise amounts of the paint mixture into half-shells, which are then sealed together to form complete paintballs.

A soft gel encapsulation machine is commonly used to manufacture gelatine shells. This machine consists of two large, rotating drums, each containing a continuous sheet of liquid gelatine. As the drums rotate, they press the gelatine sheets together, forming a thin film. A nozzle between the drums deposits the paint mixture onto one of the gelatine sheets in measured droplets.

Sealing and Cutting

The paint droplets become encapsulated within the gelatine film as the two gelatine sheets are pressed together. The soft gel encapsulation machine uses heat and pressure to seal the edges of the half-shells, forming complete paintballs. A cutting mechanism then separates the individual paintballs from the continuous gelatine sheet. This process is exact and requires careful calibration to ensure the paintballs are uniform in size and shape.

Cooling and Hardening

The newly formed paintballs are still soft and fragile at this stage. They are conveyed through a cooling tunnel, where they harden as the gelatine or polymer material solidifies. This step ensures the paintballs maintain their shape and integrity during storage, handling, and use.

Quality Control and Inspection

Quality control is a critical aspect of paintball manufacturing, as size, shape, and shell thickness variations can affect performance and safety. After the paintballs have cooled and hardened, they undergo a series of inspections and tests to ensure they meet the required specifications.

Visual Inspection


Paintballs are visually inspected for defects such as malformed shells, inconsistent colouration, or visible seams. Any not meeting the established criteria are removed from the production line.

Size and Roundness

The size and roundness of paintballs are essential for proper performance in a gun. Manufacturers use precision instruments to measure the diameter and roundness of the paintballs, ensuring they fall within the acceptable tolerances.

Shell Thickness and Brittleness

The thickness and brittleness of the paintball shell can significantly impact performance, as a shell that is too thick may not break upon impact, while a shell that is too brittle may break prematurely during storage or handling. Manufacturers use specialized equipment to test the shell thickness and brittleness, ensuring that they meet the desired performance characteristics.

Packaging and Storage

Box of paintballs

Once the paintballs have passed all quality control tests, they are ready for packaging. Paintballs are typically packaged in bags or containers with a moisture-absorbing desiccant to help prevent the shells from becoming soft and sticky due to humidity. The packaged paintballs are then stored in a temperature-controlled environment to maintain their quality and performance until they are shipped to retailers and Activity Centres.

So there you go. Next time you are playing paintball near Leeds or York, remember the intricate process of how your paintball was made.

More interesting pages

Kids Paintball Games
What type of paintball player are you?

Kids Paintball

Book kids Laser Tag

16 Celebrities who regularly play paintball

Scroll to Top