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.
​
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.
Sustainability
In recent history, there has been a clear demand for green energy and a sustainable business model that respects our planet. We are not oblivious to the energy transition and are doing everything possible to also become a modern company in this regard. Sometimes it's just a small difference, but just like in the development of the bicycle, marginal gains are also achieved in the story of sustainability.
​
Changes to the packaging
​
For the packaging, the Belgian Cycling Factory collaborates with the leading packaging group, VPK Group. Together, they have implemented some eco-friendly adjustments. Previously, we used insulation foam, which was very environmentally harmful in terms of production and waste. Now, we use a sturdy outer box containing smaller boxes that hold small parts and simultaneously protect and secure the bike.
Another adjustment is the decision to rotate the handlebars, which take up a lot of space, and partially fold them under the frame without damaging the integrated cabling. Everything is packed very compactly, and space is used much more efficiently. Where a truckload of cardboard used to leave the factory, now it's just a pallet. Less storage space means more room for other things and fewer trips.
Additionally, there are no staples in the box, so there is no metal pollution. These are all small adjustments in terms of packaging, but together they make a difference.
Other adjustments we have made on our journey towards a more sustainable world
-
We are utilizing a new technology that allows us to carry out our activities with less energy consumption and are contributing to the '100% Limburg Bike' project. With this technology, we can produce carbon components robotically, which is both safer and more environmentally friendly. These components can be recycled 100% thanks to the use of thermoplastics. When the product is used up after 20 or 30 years, we can produce two new basic components again with very little energy.
-
We produce as much as possible in our own factory and only commence production upon order placement, ensuring optimal efficiency.
-
We utilize solar panels that generate 323,136 kWh of electricity. Additionally, we encourage the use of electric vehicles among our staff, with charging stations available at the factory. This motivates everyone in the company to contribute to a green future.
-
Of course, we also contribute to a healthier future with our brands. Every necessary trip by bike is one less car ride. By offering custom-made bicycles, we provide a solution to the mobility issue. Everyone gets the chance to commute in an environmentally friendly way, thereby reducing CO2 emissions.