Although forms of pre-packed
paper cartridges go back to the Middle Ages, these were for several centuries made up by the shooter or a servant, rather than being mass-produced, requiring a container for the gunpowder, which came loose. Unlike modern cartridges, these were not inserted into the gun themselves, but were rather a pre-measured amount of powder stored in a paper wrapper, sometimes with the ball included as well. Loading the gun involved tearing open the package, emptying the powder into the muzzle and pan, inserting the ball with the paper doubling as wadding, and then ramming home the charge. This was somewhat faster and more convenient than measuring out a powder charge each time, especially in a combat situation. However, there was no large-scale manufacturing of these cartridges until the 19th century, and even then the benefits mostly lay with military use; the added cost made them less popular with civilian shooters until the advent of the self-contained
metallic cartridge and the
breech-loader. While loading a muzzleloader, an important safety concern was that when reloading a muzzle-loading gun soon after a shot there might be small pieces of wadding burning in the muzzle, which would cause the new load of powder to ignite as a flash. So long as no part of the loader faced the end of the barrel this was not likely to lead to serious injury, but if a spark reached the main supply in the powder flask a dangerous, even fatal, explosion was likely. General
Sir James Pulteney, 7th Baronet, was one such victim; he died in 1811 from complications after losing an eye when a powder flask accidentally exploded in his face in
Norfolk.
Charles Kickham, prominent in the
Irish Republican Brotherhood, grew up largely deaf and almost blind as the result of an explosion when he was 13, in about 1840. Various precautions were taken in the design and use of powder flasks to prevent this from happening, and expensive examples from as early as the 16th century usually have springs to automatically close the dispensing spout (this is much less common with the cheaper horn type). Modern manuals on muzzle-loading guns all say the flask should never be used to pour powder directly down the muzzle, to avoid dangerous overcharging and possible burst barrels, but from the English sporting press of the 18th and early 19th centuries, it is all too clear that this was then common practice, resulting in many accidents. Some
YouTube videos demonstrating loading maintain the old traditions. Instead, the powder should be poured into an intermediate container known as a charger or powder measure. Sometimes, the cap to the spout represented the measure, especially for priming flasks. Sometimes, the spout itself was the measure, with a sliding device to shut off the supply at the base, as well as a cap. This type became the norm in the mid-19th century. High-quality guns would often have come with a matching flask, chargers, and other accessories. Many flasks have small rings for a cord, which was slung around the neck to carry them, especially before large pockets on hunting clothes arrived in Europe in the 18th century. Some examples have original elaborate cords with knots and tassels. During roughly the 18th century, paper cartridges became more and more popular, and a higher proportion of flasks made were the smaller priming variety, which were still required. It appears that the
British Army in the
Peninsular War, despite regulations specifying the issue of powder horns and priming flasks, found the former inferior in action to cartridges, with the measuring spout prone to get detached and lost, and informally switched to cartridges during the war. The powder flask was finally rendered obsolete by the spread of
breech-loading guns and the innovations brought about by
Hall,
Sharps,
Spencer, and the later development of self-contained cartridges that were developed and marketed successfully by
Oliver Winchester, after which manufactured cartridges or bullets became standard. Powder flasks were also used for priming naval cannon; such a flask would be as large as, or even larger than, a main flask for a personal sidearm. The large, rectangular boxes from which the main muzzle charges for cannon were scooped are called powder boxes; these were used either when making up cartridges in advance, or loading loose powder when firing. ==Decoration==