Tag Archive: belgian cycling factory

  1. Nukeproof General Manager discusses the brand’s new chapter

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    Source: Belgian Cycling Factory

    Renowned mountain bike brand Nukeproof, which was acquired in February 2025 by LEVA-EU member Belgian Cycling Factory (BCF), is making a transition from a direct-to-consumer model, to a global dealer and distributor network under the guidance of Global General Manager, Russell Merry.

    The Nukeproof brand is long-established, founded in 1990 in the USA, and has a strong reputation with both elite riders and keen amateurs, thanks to cutting-edge geometry and durability. The Nukeproof product line-up includes electric trail/all mountain and enduro models, as well as a variety of non-electric MTB categories for adults and children.

    Asked by BCF about new priorities for Nukeproof under the BCF umbrella, Merry stated:

    “We have pivoted Nukeproof from a consumer direct brand, sold globally by Chain Reaction Cycles and Wiggle, to a dealer and distributor-led brand through the BCF network. This is a dramatic change, but one that has seen dealers genuinely surprised by the demand for Nukeproof products and the passion for the brand from riders who previously didn’t visit their local shop for Nukeproof.“

    “We are putting Nukeproof in front of dealers at shows such as Velofollies and exhibiting at the Taipei Cycle Show. As of March 2026, we have 10 new distributors and over 300 BCF dealers recruited.”

    The conversation was conducted ahead of the recent news that seven new partners were added to the Nukeproof distribution network, including new channels for the Southern Hemisphere in Australia and New Zealand. When asked about the new distribution model for Nukeproof under the BCF umbrella, Merry stated:

    “We have transitioned from a UK-based mail-order brand to a distributor and retailer-led model, so having local experts in every country is key. In the UK and many parts of Europe, we have our own offices, but we are not experts in regions such as South America or Asia. Therefore, we work with the best distributors to deliver the best local experience, not a bike in a box shipped from the other side of the world.

    “If I were a bike dealer, I would make sure I was the official dealer in my area now, because the journey Nukeproof is on is to become the most successful MTB brand in the world within five years. With the backing of BCF and the team we have in place, that ambition is absolutely achievable.”

    Merry was also asked about additional models that may be in development, and dropped hints about new products in their eMTB range, as well as highlighting the benefits of purchasing through independent bicycle dealers:

    “We know the e-MTB market has seen oversupply, but new motor suppliers will bring innovation, matched with our frame developments. This will encourage riders to consider full-price products again because they have genuinely moved forward.

    “We are open to new technology and are working with new vendors to produce carbon and alloy frames in new ways, improving both performance and pricing. Nukeproof has four new Tracker hardtails at €1,000 and below, new kids’ bikes, and a new 170mm suspension bike called the Tracker FS at €2,499, bringing value back to mountain bikes so riders can once again buy from IBDs rather than online brands and still get a class-leading product.”

    The full interview can be read here.

  2. BCF adds new partners to Nukeproof distribution network

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    Source: Cycling Industry News

    LEVA-EU member Belgian Cycling Factory (BCF) has extended the distribution channels of its brand Nukeproof, with seven new partners in Australia, New Zealand, Vietnam, Singapore, Philippines, Bulgaria and Israel.

    After first announcing its network expansion in December 2025, it has been announced that more partners will be joining the Nukeproof network.

    Nukeproof’s General Manager, Russell Merry, has said the following about the addition of seven international partnerships to the Nukeproof network.

    “We are delighted to appoint an additional seven distributors, bringing our total to fourteen globally for Nukeproof. We are excited to welcome them all into the BCF family, especially on behalf of riders in the Southern Hemisphere who have been asking when they can get Nukeproof in Australia and New Zealand since we relaunched,”

    The following statement was made by Jochim Aerts, Founder and CEO of BCF, in alignment with the announcement.

    “As an independent, family-owned business, BCF has made a clear commitment not to compete with its customers by selling directly to consumers. This retailer-only approach strongly resonates with distributors and dealers seeking premium brands with global reach and a sustainable, long-term vision,”

    “Partnering with strong local distributors who truly understand their home markets is the right way to bring Nukeproof back to where it belongs.”

    Nukeproof’s extended global network includes the following new partners:

    • Apollo Bikes – Australia
    • Worralls – New Zealand
    • Premium Distribution – Vietnam
    • Spectrum Cycle – Singapore
    • Speedtrial Cycle Centre – Phillippines
    • One Distribution – Bulgaria
    • OR Cycling – Israel

    Belgian Cycling Factory and Nukeproof at Eurobike

    BCF will be introducing new e-bikes equipped with Avinox and Bosch systems, with prices ranging from €4,499, a new enduro bike priced from €2,499, innovated to access a wider range of riders, which Nukeproof’s new partners will market in their respective regions.

  3. CIXI partners with Eurobike, while Greenway and BCF showcase innovations

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    Source: Eurobike, CIXI

    CIXI is partnering with Eurobike for its testing area and will be premiering its new Active Pilot digital ecosystem. Fellow LEVA-EU members Greenway and Belgian Cycling Factory will also be demonstrating their latest innovations and products at the show in Frankfurt from 24-27 June 2026.

    Eurobike has stated that its 2 km test track has been taken to a new level, referencing CIXI’s motto: “GO CHAINLESS – Powered by CIXI”.

    On LinkedIn, CIXI has expressed that visitors to Eurobike will have the opportunity to test a diverse range of vehicles equipped with its groundbreaking technology and experience its new Active Pilot digital ecosystem. It invites OEMs, fleet operators, and dealers to explore how its PERS Kits can boost active mobility.

    CIXI will be at Open Air F12 and Booth B16.

    Registration for the test track can be accessed through the Eurobike website.

    Greenway at Eurobike 2026

    The battery specialist will be there presenting its weld-free battery and fast-charging technology at the event.

    The weld-free battery, which has a 30% longer battery life, reimagines how batteries are designed and built. The absence of welding means that circularity is built in, with the battery able to be fully disassembled, repaired, and recycled.

    Greenway will be demonstrating how it is advancing the e-bike lithium battery ecosystem at Hall 8 H36.

    Belgian Cycling Factory at Eurobike 2026

    BCF will be showcasing its latest bikes and technology across all four of its brands Ridley, Eddy Merckx, Nukeproof and Aeres.

    At Hall 12.0, Booth D99, its team will be on hand to introduce new products, answer questions and discuss opportunities.

  4. Belgian Cycling Factory introduces new Aeres Antwerp PL5

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    Source: Aeres bikes

    The LEVA-EU member has announced that its Aeres brand has a new addition to its range, a cutting-edge e-bike model innovated to deliver smooth and comfortable rides for daily urban commuting and light touring.

    Developed at BCF’s factory in Beringen, Belgium, the new Aeres Antwerp PL5 is described by Belgian Cycling Factory (BCF) employees as delivering “More power, less weight”, boasting the following features for effortless rides:

    • Bosch Performance Line with Powertube battery
    • Shimano Nexus 5 with Gates belt drive
    • Redesigned lightweight frame
    • MIK HD carrier system

    More about the standout features of the Aeres Antwerp PL5

    As an e-bike created for daily use, urban riding, and light touring, this e-bike’s Bosch Performance Line mid-motor provides smooth and natural pedal assistance for powerful and intuitive rides. For improved comfort, the bike features a low-step-through lightweight frame and an upright riding position. Its combination of a Shimano Nexus 5 internal gear hub with a Gates belt drive brings a durable and low-maintenance drivetrain. The Aeres Antwerp PL5 also features an MIK HD carrier that’s compatible with a wide variety of accessories for carrying loads of up to 27 kg.

    More information about the Aeres Antwerp PL5 can be accessed on the Aeres website.

  5. Belgian Cycling Factory founder interviewed by De Standaard

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    Sources: De Standaard, Belgian Cycling Factory

    The LEVA-EU member is Belgium’s largest bicycle manufacturer and anticipates a turnover of 80 million euros in 2026. Its founder, manager and owner, Jochim Aerts, was interviewed by major Belgian newspaper De Standaard about the company’s beginnings, milestones and factory capabilities.

    Aerts’ Belgian Cycling Factory (BCF) boasts a business portfolio of bicycle brands: Ridley, Merckx, British mountain bike brand Nukeproof, and, more recently, electric city bike company Aeres.

    A former cyclist in the 1980s, Aerts has applied his longstanding passion and expertise in bicycles to make BCF a highly successful business. In 2025, the company reported a 30% turnover increase and expects the same for this year, with a total turnover of 80 million euros, as it anticipates reaching 100 million euros by the end of 2027.

    “As soon as we are operating at full capacity, we will need a hundred extra workers,” says Aerts.

    The beginnings of BCF

    Aerts started working on and painting bicycles when he had to use his brother’s bicycle, leading him to build on these skills as a part-time profession, which involved him welding and painting racing frames for Bioracer, while simultaneously training and participating in cycling races.

    The demand for his bicycle expertise took the lead over his racing ambitions, with other brands requesting his painting work, which required him to employ staff and secure contracts.

    Then in 1997, Aerts decided to create his own bicycle brand, Ridley, naming it after his favourite director, Ridley Scott. The company grew rapidly with the help of Paul Kumpen and the Limburg Reconversion company through the years, which Aerts has since bought out, resulting in him owning 97.5% of the company.

    Having faced challenges alongside the rest of the bicycle industry in recent years, Aerts remains confident about BCF’s abilities in staying up to date with advanced innovations, highlighting that it has been selected as equipment sponsor for the UnoX racing team.

    “We have good engineers, and our suppliers make top-tier frames that can perfectly compete with the best brands in the peloton. The proof: the Norwegian Tour team UnoX chose us as their equipment sponsor, and some teams with a different bike sponsor still opt for our time trial bikes.”

    Effects of the pandemic on BCF

    The fluctuation of demand from the coronavirus situation led many companies to produce an oversupply of bicycles that became unsold, resulting in numerous bankruptcies in the industry.

    Aerts anticipated the oversupply, ahead of time, and drastically reduced 2023 orders. While industry players experienced great difficulties in the post-pandemic era, Aerts saw industry opportunities in acquiring Nukeproof (saving it from bankruptcy) and strengthening its sales team.

    “The downturn means that in recent years we have been able to recruit highly experienced international salespeople from major bicycle brands. As a result, we can collaborate with many more bike shops abroad. Our model, in which we do not require bicycle retailers to place large advance orders, is catching on increasingly. Moreover, the problems at other brands mean that space is becoming available in stores, where we can then display our range.”

    Expanding the Belgian Cycling Factory portfolio

    After a challenging few years, Aerts has also outlined other milestones, such as the company innovating cheaper Ridley models through Asian manufacturing, re-launching its Merckx brand in 300 stores, as well adding the Aeres electric city bike to its portfolio.

    “Many feel that we are very late to introducing electric bikes, but I also launched Ridley decades after the racing bike was invented, so when is it ever too late? Our engineers have thoroughly studied other electric bikes and drawn lessons from them for potential improvements.”

    BCF’s advanced factory capabilities for fulfilling customer demand

    Its factory, next to its Beringen headquarters in Belgium, employs 80 workers and produces approximately 120 bicycles a day, with only the more expensive models being assembled there. It also has a production facility in Moldova, as well as sites in China and Vietnam, with the help of Taiwanese suppliers.

    Aerts has noted that for the aluminium frames of its electric bikes, it is looking for partners closer to Belgium. Currently, the company is working on a project with Dutch company VDL to produce frames from recycled aluminium using highly automated production.

    At its dust-free paint shop in Beringen, it also provides custom frame painting for customers with a wide selection of options and variations available.

    In terms of assembly, its digital factory processes are very efficient, with Aerts integrating methods he learned from car factories. It rolls off a bicycle off the line every four minutes, thanks to ten people working on an assembly line, with the help of sub-assembly lines for different components, such as handlebars and wheels, for example.

    The company is already running a second assembly line in Beringen for peak periods, and plans to build a third one to fulfil expected demand increases.

    “Capacity will be increased from 30,000 to 80,000 bicycles per year. When all the new lines are running, around a hundred extra workers will be added,” says Aerts.

    Aerts’ comprehensive interview can be read in full online on De Standaard.

  6. How Belgian Cycling Factory makes its paint process more sustainable

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    Source: Belgian Cycling Factory

    The LEVA-EU member continuously looks for ways to help it operate more efficiently and sustainably. Most recently, it has revealed how the small improvement of re-using masking plugs in its paint shop has made a significant impact.

    Belgian Cycling Factory’s in-house paint shop operates at its Bike Valley site in Beringen, Belgium, where it gives thousands of bikes a unique finish every year according to customer preferences.

    Finding a way to re-use masking plugs

    Rubber masking plugs are used during the painting process to seal frame openings to keep them free of paint. Normally, part of the process involved discarding the plugs because they were covered with paint residue after use.

    Benjamin Mertens, BCF’s Painting Operations Manager, evaluated if the discarding of the plugs was really necessary and questioned whether they could be cleaned or used again for internal use.

    “Manually removing the paint residue is very labor-intensive. That’s why we started looking for another solution to make the plugs reusable.”

    He uncovered a cleaning solution for the plugs by placing them with stones in a rotating concrete mixer. This process caused the paint residue to break off and wear away gradually, leading it to eventually becoming a professional method for arranging plug re-use.

    A visible difference in encouraging sustainable production

    With the new cleaning solution in place, masking plugs are now re-used several times, which not only decreases waste but also brings significant cost savings. To put it into context, each frame requires 9 masking plugs during the painting process, therefore a noticeable difference is achieved when the plugs are re-used for tens of thousands of bikes per year.

    The company summarises that the new method demonstrates how innovation often starts on the shop floor, with Mertens aspiring to uncover further optimisations.

    “I always try to look at the painting process with a fresh perspective. If we can work more efficiently or more sustainably somewhere, we will explore it.”

    Belgian Cycling Factory’s COO, Robby Stas, states that this new initiative perfectly aligns with the company’s vision in becoming more sustainable.

    “We will implement this as a standard process in our paint shop. It’s a great example of how a smart process improvement can simultaneously be more sustainable, more efficient and cost-saving.”

  7. Christina Hsu bridges BCF European and Asian connections

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    Source: Nieuwsfiets Image credit: Nieuwsfiets

    Last July, Christina Hsu joined LEVA-EU member Belgian Cycling Factory’s team as General Manager of BCF Asia. Drawing on her extensive experience in the cycling industry and her deep understanding of Asian production processes and European business structures, Hsu plays a significant role in strengthening the company’s international organization.

    With a career spanning supply chain coordination, product development, sourcing, and quality control, Hsu brings broad expertise to her position. She has also gained experience in quality-focused roles outside the cycling sector, which she believes highlights the unique nature of the industry. “The bicycle industry is very human,” she says. “It’s a global industry, yet surprisingly small. That means relationships matter. Trust is crucial, and many people work together for years.”

    According to Hsu, the sector is distinguished by its informal and personal approach to collaboration. “It’s not just business. Real friendships are formed. You can’t afford to make any mistakes, because reputation is everything. If you do something wrong, everyone eventually knows about it,” she continues. This personal dimension, combined with the sense of building something collectively, makes the work particularly meaningful. “Once you’re in the bicycle industry, you basically can’t get out,” she says with a smile. “And that’s perfectly fine.”

    Facilitating important retailer relationships

    Hsu is well known to many retailers and has led multiple dealer trips to Taiwan, acting as a guide and cultural intermediary. These visits extended beyond factory tours. “It was never just ‘Look, this is where the product is made,’” she explains. “I felt it was important to also provide context: the culture, the way of working, how decisions are made, and why processes in Asia sometimes differ from what people in Europe are used to.”

    She regards this mutual understanding as essential. “From Europe, it sometimes seems like you can order a product with a single click and have it delivered the next day. But behind that click lies a completely different reality in Asia, with complex supply chains, planning, and interdependencies. Translating expectations, cultures, and working methods—that’s what I did then, and what I still do now.”

    Strengthening BCF’s Asian operations

    Hsu officially joined Belgian Cycling Factory in July, following a shared recognition of how her expertise could support the company’s growth. “There was an immediate understanding of where I can add value,” she says. “BCF has grown strongly and is further professionalizing its international structure. A key development within BCF is the increasing in-house management of its Asian activities. Where much used to be handled through trading companies, we now collaborate directly with partners in Asia. This requires on-site presence, knowledge, and coordination.”

    Based in Asia, Hsu oversees sourcing, supply chain coordination, product performance, quality control, and logistics. Direct shipping has become increasingly significant, particularly for markets such as Australia and New Zealand, where bicycles are delivered directly from Asia. Her responsibilities extend across Taiwan, China, Vietnam, Cambodia, Indonesia, and Bangladesh, involving extensive travel, an aspect of the role she views positively.

  8. Belgian Cycling Factory expands sustainability initiatives

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    Source: Belgian Cycling Factory

    The LEVA-EU member has strengthened its sustainability strategy through a wide range of initiatives aimed at reducing environmental impact, improving working conditions, and promoting responsible manufacturing.

    While cycling itself is already recognised as one of the most sustainable modes of transport, the Belgian bike brand emphasises that its responsibility extends far beyond the product by continuing to invest in renewable energy, cleaner production technologies, waste reduction, and sustainable mobility for employees.

    Renewable energy investment and sustainable transportation

    The company’s most visible sustainability investments can be found at its headquarters in Beringen, where 1,584 solar panels have been installed on the roofs of its production facilities. The installation delivers a total AC capacity of 376,200 watts (approximately 376 kW), generating enough renewable electricity annually to supply between 110 and 130 average European households.

    Belgian Cycling Factory has stated the solar installation prevents an estimated 180 to 200 tonnes of CO₂ emissions each year compared with conventional grid electricity. By producing a significant share of its own renewable energy, the company reduces reliance on fossil fuels and structurally lowers its operational carbon footprint.

    The company’s sustainability programme also includes an employee cycling allowance scheme and is gradually electrifying its vehicle fleet, supported by on-site charging infrastructure.

    Water-based paint technology in production

    Another major sustainability initiative is the conversion of the company’s in-house paint shop to water-based paint systems. These coatings contain approximately 90% fewer volatile organic compounds (VOCs) than traditional solvent-based paints, significantly improving indoor air quality while reducing environmental impact.

    Plant Manager Jan Van Daal explains:

    “Water-based paint allows us to apply a thinner yet higher-quality coating layer, which reduces overall material consumption. While the unit cost is higher, we need less product per frame. In addition, we no longer require thinners, as the paint can be diluted with water. This results in a substantially lower environmental footprint.”

    The company says this investment enables continuous improvement in both workplace safety and environmental performance, without compromising product quality.

    Reusing protective frame packaging

    Sustainability efforts also extend to daily operational practices. In the assembly department, protective packaging materials used during production are actively reused. The protective bags are repurposed as bike protection sleeves and handlebar covers, helping to reduce waste and maximise material usage.

    The programme enables the reuse of approximately three tonnes of protective plastic material each year.

    Product longevity and responsible manufacturing

    Belgian Cycling Factory also highlights product longevity as a central pillar of its sustainability strategy. The company offers a lifetime warranty on frames, encouraging long-term use, repair, and responsible ownership.

    Recognising that carbon fibre production involves complex global supply chains and transport-related emissions, the company views extended product lifespan as one of the most effective methods of reducing the overall environmental footprint of a bicycle.

    A long-term commitment

    Belgian Cycling Factory describes sustainability as a continuous daily process as it remains committed to advancing environmental performance while continuing to deliver high-quality, innovative products to cyclists worldwide.

  9. Ridley receives Design & Innovation Award 2026

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    Source: Ridley, Design & Innovation Award

    Only a few days after launching the E-Noah (the first electric version of its aero race bike), Ridley, which is a brand of LEVA-EU member Belgian Cycling Factory, won the prestigious design award in its road bike category.

    The E-Noah blends top level performance with discreet electric assistance in a light, aerodynamic design that is kept under 11 kg, thanks to its TQ HPR40 system. Its battery and motor are fully integrated, resulting in the E-Noah having a very similar appearance to traditional racing bikes. It brings 40 Nm of torque and 200 W of extra power, for a powerful and intuitive riding experience which can be personalised via the TQ app.

    E-Noah’s Design and Innovation Award: what it means

    In the cycling industry, this award is seen as a genuine mark of excellence and a standard that every engineer strives to achieve. The success follows from other Ridley models that have received the Design & Innovation Award, after ASTR RS last year, and the Grifn in 2023.

    The jury shared the following about the E-Noah:

    “For road cyclists looking for a lightning-fast aero bike with subtle support, the Ridley E-Noah builds a bridge that didn’t exist before,”

    “At its core is the seamless integration of the lightweight TQ HPR 40 motor into an aero frame straight from the pro peloton. The motor and battery are tucked away so neatly they’re nearly invisible, while the aerodynamically optimised frame shapes don’t just boost speed – they also help expand the bike’s range of applications.”

    Discreet and intuitive aerodynamic performance for electric and road bike enthusiasts

    The jury praised the E-Noah’s sleek design that’s optimised for powerfully versatile performance:

    “At its core is the seamless integration of the lightweight TQ HPR 40 motor into an aero frame straight from the pro peloton. The motor and battery are tucked away so neatly they’re nearly invisible, while the aerodynamically optimised frame shapes don’t just boost speed – they also help expand the bike’s range of applications.”

    Also highlighted by the jury was the E-Noah’s natural riding feel and motor performance:

    “On top of that, the motor impresses with smooth responsiveness and a natural cut-off, making the E-Noah a convincing performer even beyond the 25 km/h threshold.”

    “This makes the Ridley a top choice not just for e-bike fans, but above all for passionate road cyclists who want discreet support without compromising on performance or speed above 25 km/h. It’s a combination that won over the jury, earning praise for its sleek motor integration and efficient aero profiling.”

    More about the E-Noah can be accessed on the Ridley website, and the jury’s full verdict is listed on the Design & Innovation Award website.