Over 8 million individual components are stored in either of the two warehouses at any one time.

Their product value is equivalent to around €16 million.

Thanks to a sophisticated warehouse management system, the forklift truck operators can always find the product they need quickly, without having to search high and low.

Everything our mechanics need is stored here, from the smallest screw to bike frames and wheels.

The tube frames are tested for accuracy and the form corrected by hand if necessary.

Threads which are necessary to hold screws in the frame are cut.

Frames are precisely measured and checked again on a sample basis.

In some models, mounts for chain guards and cables are brazed on.

The frames then wait on trucks to be painted.

The prepared frames are electrostatically charged...

... and sprayed with fine plastic granules. The charge on the frames attracts the powder.

The granules then harden in the drying oven to form a powder coating.

It is now that the actual paint is sprayed onto this primer. Solvent–free, water-based paint is used to protect the environment.

The paint flows onto a rotating disc, where it is so finely atomised that it forms a perfect coating on the frames.

After the first drying process, multi-coloured frames are masked with tape by hand...

... and painted a second time.

Once the paintwork is complete, the lettering and decoration are applied by hand and sealed with another layer of powder coating.

First the spokes are threaded into the hubs.

This process is fully automated.

Next the spokes are screwed into the rims. Here a worker is inserting the spokes into the holes pre-determined by the machine.

The semi-finished wheels are conveyed to the next station.

Here they are trued fully automatically, after which they rotate perfectly.

At this point the rim tape, tube and tyre and sprockets are fitted.

The finished wheels are stored on trucks ready for final assembly.

In the "handlebar building" department, the handlebars are pre-assembled and the brake and gear levers screwed on.

Brake and gear cables are attached and secured.

Finally, the handlebar grips are mounted or handlebar tape applied. In total, almost 4,000 different combinations of handlebar shapes, brake levers, bells etc. are possible.

Like the frames, wheels and handlebars, the components are taken on trucks to the final assembly area.

Here all the parts are assembled step by step to form a complete bicycle.

The wheels are inserted...

... mudguards fitted...

... and, of course, the electric motors mounted.

This is how the Kalkhoff bike "grows" step by step until it is complete and ready to ride.

Before the finished bikes are packed and delivered, our Quality Assurance staff check the quality of both the components and their assembly on a sample basis.

Records of these checks are kept.

Finally the Kalkhoff bikes are conveyed to the despatch area on hooks...

... and packed well protected in boxes.

In this way around 3,000 bikes leave our production facilities every day.