Processing of energetic materials into propellants explosives or pyrotechnics can be both hazardous and waste producing. Formulations are generally high solid loading and can be very viscous or difficult to mix to homogeneity. The batches generally have limited pot life and for any number of reasons batches can exceed their pot life and generate significant waste. Even under optimum conditions batch mixing requires significant clean up after each run and generates large amounts of hazardous waste. In many processes, batches are made and distributed to the ordnance case. Continuous processes offer significant advantages and mix in case technologies are potentially a big improvement. SERDP and ESTCP have been exploring a variety of methods to improve on the formulation and processing of energetic materials.