Market: As one of the few bicycle manufacturers, the German forge von Drössiger offers its customers (almost) complete freedom in the color design of their own bikes. However, this means that each wheel is a one-off product and the production processes have to be perfectly coordinated. Our look behind the scenes of the production facility in North Rhine-Westphalia shows how this works in practice.
The special thing about Drössiger bikes is that none of them come off the shelf. Each individual wheel is manufactured according to the individual color ideas of the respective customer. Either the decision about one of the countless shades is made directly at the retailer or in the color configurator on the homepage. After that it takes about two weeks to manufacture the desired bike in the production facilities in Eschweiler.
Our look behind the scenes at Drössiger shows the individual production steps that each bike goes through - from a simple code number on a computer screen to the finished bike on the first tour.
Step 1: Sales
Before the production of the new bike can begin, the course has to be set in the sales office. The dealer transmits the bike code from the color configurator that the respective customer had selected. This means that all the necessary information is already available and production can start.
Step 2: Decor print
At the beginning of the production process are the decors for the new bike. The color wedges and lettering are printed on the film using special printers. The next step requires a sure instinct: each decor is cut out by hand. It takes a lot of care and steady fingers so that the detailed decals can be applied neatly to the frame; after all, not a single I point should be missing at the end!
Step 3: picking
After the decor has been printed, the order is sent to the warehouse. The right attachments for the bikes are available on more than 5.000m². Each bike consists of a multitude of individual parts that are collected and made available by the order pickers. The complete bike is slowly but surely taking shape and the raw frames, forks and the various parts are waiting for their next station on special trolleys.
Step 4: Powder Egg
Once all the individual parts have been picked, the raw frame goes to the powder shop. Here the desired base color is applied and fired in a special oven. Then the decals are used. The carrier film can only be removed when the decorations are perfectly in place. In order to seal the overall work of art, the finish is then applied in matt or glossy and the frame is put in the oven a second time. This double powder coating not only looks high quality, it also makes the frame extremely durable. The use of wet paint is deliberately avoided, as this is processed with highly toxic solvents and is therefore extremely harmful to people and the environment.
Step 5: Assembly
The decors have been printed, all parts have been commissioned and the frame has been powder-coated - now the assembly is all about the nitty-gritty. Before the add-on parts are attached, the frame only makes a brief stop during milling. The fitters then completely assemble the bike, coordinate all parts and check all functions. Only when the final inspection ensures that everything fits perfectly is the bike partially dismantled in order to prepare it for transport to the dealer.
Step 6: Logistics
To ensure that nothing gets scratched during transport, the bike is carefully packed and handed over to the shipping company in sturdy cardboard boxes. The bike has now completed the last station. The dealer then takes care of the final adjustment and the first tour can begin.
Carsten says
Wheels are TOP. Unfortunately, current cyclocross and racing bikes are missing!
Drottier says
Hi Carsten,
Thanks! We are currently working on a new gravel bike that will be released in the middle of the 2017 season. So...stay tuned! 🙂
Happy_Cyclist says
Well, I don't own a Drössiger myself, but it's the perfect recommendation when someone from my circle of friends asks me "tell me, what kind of bike should I buy?" There's the right one for everyone and with the free choice of color ... perfect!