THE BIGGEST CYCLING FACTORY IN BELGIUM​
SUPPLY CHAIN EXCELLENCE
Modernization of our BCF-factory is a continuous process to provide the best inclass supply chain. Our in-house paint shop allows customization based on the rider preferences and an instant production framework.
QUICK RESPONSE MANUFACTURING
In our DNA is the permanent search of innovation, as a way of doing things more efficiently. Our QRM approach allows us to quickly adapt to customer demands and market changes, enhance flexibility & to reduce lead times.
INCREASING YOUR BENEFITS AND PROFITS
Sustainability is an essential part of our social & environmental responsibility towards future generations and at BCF we take that very serious. Operating on green power solar panels provinding 323,136 kWh, a 100% electric company car policy and our custom-sized eco-box without the use of ANY foam of plastic.
Factory in Belgium
Located on the Beverlosesteenweg in Beringen, the Belgian Cycling Factory is a hub of bicycle activity, assembling bikes in various colors, sizes, and weights. With an in-house paint shop, it allows customization according to customer preferences. In recent years, the factory underwent significant modernization to better serve customers.
What’s in a name… The Belgian Cycling Factory is not just a bike retailer or a gathering place for dozens of companies in the cycling industry; it is primarily a bicycle factory. The factory has weathered the challenges of the COVID-19 crisis and, if anything, has emerged stronger. Due to a global parts shortage during the pandemic, plans for a hypermodern factory in Beringen were accelerated.
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The modernization occurred in three phases: the paint shop was completely renewed, a new assembly unit was added, and a new logistics system was built around it. This significantly increased daily production, enabling the offering of a full range of different bikes in the long run. This evolution is expected to lead to a significant advancement in e-bikes and bikes for commuting. The launch of Grifn, an all-terrain bike, was a promising first innovation.
Our production starts immediately after your order is placed. Our factory operates on green energy, with solar panels providing up to 323,136 kWh. The parking area features numerous electric vehicles, reflecting our commitment to sustainability. This commitment extends to custom-sized bike boxes and collaborations with partners who share our values. Additionally, we prioritize the use of recyclable materials.
Factory in Moldova
Most frames are produced in Asia, and with a paint shop in Moldova, BCF caters to local needs. This additional production was initiated in 2008 to meet the desires of customers globally, allowing them to choose their bike's colors through our configurator. BCF increasingly aims to conduct more activities in its own region, emphasizing this ambition through collaboration with the Dutch company VDL in Breda, where, eventually, bike frames will be produced
R&D and Innovation
The R&D department of the Belgian Cycling Factory has garnered much praise, earning awards for the Grifn, Kanzo Fast, and Kanzo Adventure. Numerous significant victories and legendary performances on our bikes confirm the effectiveness of our work.
One of BCF's strengths is optimized geometry, a crucial factor in cycling, determining how a bike responds to riding behavior. Our engineers carefully consider which geometry suits each bike and rider. Aero bikes respond instantly to impulses, emphasizing speed, while enduro bikes prioritize a comfortable posture.
Another example of our R&D department's dedication is the introduction of mudguards and lights. This feature quickly transforms your bike into an ideal winter bike, ensuring dryness and safety in rain and snow while making you visible to others on the road. The internal dynamo routing, using a dynamo hub, enables the lights, with cables concealed in the fork leg and seat tube. The same thoughtful approach is applied to tire width choices, depending on the terrain. Our team meticulously considers every millimeter, testing and refining choices by taking the bikes outdoors.
Details and trends
Details make the difference, evident at BCF, where nothing is left to chance. Covers are provided for unused attachment points, preventing bolts from protruding from the bike. These attachment points offer the flexibility to customize your bike with various bags and bottle holders, allowing customers to choose a personalized setup for comfortable completion of long and challenging rides.
We closely follow trends in the cycling world, such as the UDH hanger, a universal solution for all rear derailleurs. This ensures immediate assistance from local bike shops for gear problems, eliminating frustrations due to longer delivery times. In recent years, the rise of disc brakes and flat fronts of handlebars has been observed, and we closely monitor and promptly respond to consumer demands.
Lastly, the material used in our bikes is crucial. Our carbon is manufactured by Toray, a world-leading company. Depending on the bike, we use 60T, 50T, 30T, and 24T carbon. It's a delicate balance to determine which carbon is used where, but BCF consistently makes a difference in crafting the best bikes. This commitment is mirrored in our aluminum bikes, which undergo a high-tech process before forming the bike. We choose a 6061-T6 alloy for its excellent scores in stiffness, metal fatigue, weight, and precision.
Smart Packaging: Protection with Purpose
At Belgian Cycling Factory, packaging is not an afterthought, but an integral part of our commitment to quality, efficiency, and sustainability. Every element is carefully considered to ensure that each bike is protected throughout its journey, while minimizing waste and environmental impact.
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Our approach starts with materials. We work exclusively with cardboard sourced from a Belgian supplier, allowing us to respond quickly while reducing COâ‚‚ emissions associated with long-distance transport. In addition, we actively reuse plastic protection from frame and wheel packaging supplied by our manufacturers. These materials are carefully cut to size, ensuring optimal protection without unnecessary waste.
The design of our packaging is the result of close collaboration with our suppliers and continuous refinement. Each box is engineered with reinforcements placed exactly where needed to guarantee maximum protection. Inside, a dedicated compartment for small parts also serves as a structural element, strengthening the overall construction. The dealer kit is strategically positioned on the rear wheel, securing the bike firmly in place and preventing any movement during transport.
Efficiency plays a key role in our packaging strategy. The dimensions of our boxes are optimized to fit perfectly within standard transport conditions, eliminating empty space and reducing the risk of damage. This precise fit allows for maximum loading efficiency, with boxes arranged seamlessly and stacked securely for transport.
Our packaging is developed exclusively for dealer distribution. By avoiding consumer-facing branding, we reduce unnecessary costs while also lowering the risk of theft. This focused approach ensures that our products reach their destination safely, efficiently, and in line with our broader commitment to responsible production.
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At Belgian Cycling Factory, packaging reflects the same philosophy that defines our bikes: continuous improvement, attention to detail, and a constant drive to perform better — for our riders and for the environment.
Customer Service: Raising the Standard
At Belgian Cycling Factory, customer service plays a central role in how we deliver quality to both riders and dealers. It is where our bikes are prepared, checked, and perfected before they begin their journey and where our commitment to excellence becomes tangible.
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With the recent renovation of our workshop at Bike Valley in Beringen, we have taken an important step forward in strengthening this commitment. The new workspace is designed to support efficiency, precision, and craftsmanship at every stage of the process. Modern workstations and optimized workflows allow our technicians to operate with greater consistency and control, ensuring that every bike meets the highest standards before leaving our facility.
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What truly defines our Customer Service department is the people behind it. Our team combines hands-on retail experience with insights from the professional peloton, bringing a deep understanding of both product and rider expectations. This unique mix translates into a high-performance mindset, where every detail matters and every bike is treated with care.
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Continuous improvement is embedded in our daily operations. Through structured shopfloor meetings and close monitoring of performance indicators, we constantly refine the way we work. This approach enables us to respond quickly, improve efficiency, and maintain a consistently high level of service.
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Ultimately, our investment in this renewed workshop reflects a clear ambition: to provide reliable, high-quality service that supports our partners and enhances the experience of every rider. Each bike that leaves our workshop is the result of technical expertise, thoughtful preparation, and a shared dedication to getting every detail right.
Sustainability
In recent years, the demand for green energy and sustainable business practices has grown significantly. At Belgian Cycling Factory, sustainability is not a trend or a slogan, but a continuous commitment embedded in the way we design, produce and operate our business. Just like in the development of a high-performance bicycle, sustainability is built through marginal gains — a series of thoughtful, often small improvements that together make a meaningful difference.
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Cycling itself is already one of the most sustainable forms of mobility. Nevertheless, we believe our responsibility goes further than the product alone. Across our facilities, processes and long-term strategy, we actively invest in solutions that reduce our environmental footprint, improve working conditions and contribute to a more responsible cycling industry.
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Renewable energy and sustainable mobility
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At our headquarters and production facilities in Beringen, sustainability is clearly visible. A total of 1,584 solar panels installed on our roofs generate approximately 376 kW of renewable electricity. On an annual basis, this production equals the electricity consumption of around 110 to 130 average households and allows us to avoid an estimated 180 to 200 tonnes of COâ‚‚ emissions per year compared to conventional grid electricity.
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In addition, we actively support sustainable mobility within our organisation. Our company fleet is gradually being electrified, supported by on-site charging infrastructure. Employees are encouraged to commute by bike through a cycling allowance, with several colleagues covering long daily distances by bicycle — often on a Ridley — proving that cycling is both a practical and sustainable transport solution.
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Changes to packaging and logistics
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Packaging plays an important role in reducing environmental impact. Belgian Cycling Factory collaborates with VPK Group, a leading packaging specialist, to continuously improve packaging efficiency.
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Previously, insulation foam was used to protect bicycles during transport. This material was environmentally harmful in both production and waste processing. Today, bicycles are packed in a sturdy outer box containing smaller internal boxes for components, ensuring protection while significantly reducing environmental impact.
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Handlebars are now rotated and partially folded under the frame without damaging integrated cabling. This allows for much more compact packaging and efficient use of space. Where a full truckload of cardboard used to leave the factory, the same volume can now be reduced to a single pallet — resulting in fewer transport movements, lower emissions and reduced storage requirements.
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In addition, packaging is now completely free of metal staples, eliminating metal contamination in the recycling process. Individually, these may seem like small adjustments, but together they create a substantial reduction in waste and transport impact.
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Cleaner production through water-based paint technology
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Another key improvement is the conversion of our in-house paint shop to water-based paint systems. These coatings contain approximately 90% fewer volatile organic compounds (VOCs) compared to traditional solvent-based paints.
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This transition significantly improves indoor air quality for our employees while reducing environmental impact. Water-based paints allow for thinner yet higher-quality coating layers, reducing overall material consumption. They also eliminate the need for chemical thinners, as dilution is done with water — resulting in a cleaner, safer and more efficient production process without compromising finish quality.
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Reuse of protective materials in assembly
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Sustainability is also reflected in everyday operational decisions on the shop floor. Protective packaging materials used during frame production are no longer discarded after a single use. Instead, they are actively reused in the assembly department as bike protection sleeves and handlebar covers.
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This initiative allows Belgian Cycling Factory to reuse approximately 3 tonnes of protective plastic material per year, significantly reducing waste while maintaining safe and secure transport of finished bicycles. It is a clear example of how employee-driven innovation can turn simple ideas into practical, scalable sustainability improvements.
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Responsible manufacturing and product longevity
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Sustainability does not stop at operational efficiency. Product longevity plays an equally important role. Belgian Cycling Factory offers a lifetime warranty on frames, encouraging repair and long-term use rather than premature replacement.
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We acknowledge that carbon fibre production involves complex global supply chains and transport. Extending product lifespan is therefore one of the most effective ways to reduce the overall environmental footprint of a bicycle. Durable, repairable products retain value, reduce waste and support a more circular approach to manufacturing.
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Where possible, production is carried out in-house and only initiated upon order placement. This ensures optimal efficiency, avoids overproduction and limits unnecessary stock and transport.
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A continuous commitment
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At Belgian Cycling Factory, sustainability is a continuous journey built on hundreds of decisions — large and small — taken every day. From renewable energy and cleaner production technologies to smarter packaging, employee engagement and long-lasting products, each step contributes to a more responsible future.
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We remain committed to continuously improving our environmental performance while delivering high-quality, innovative bicycles for cyclists around the world.