From Configurator to Dealer
An Eddy Merckx Bike travels a long journey in a short time from the configurator to the dealer. Our bikes are made in Belgium: from design to assembly, almost everything happens in our very own Factory of Dreams in Beringen. We’re happy to take you through the different phases of the production process.
1. Order Picking of the Frame
Immediately after the customer configures and orders their bike, the factory process begins. Order picking takes place in the warehouse and includes the frame and fork, sometimes supplemented with the seat post and handlebars. These frames are produced in Asia, just like those of nearly all competing brands. The production of the frame is the only part of the process that takes place outside our factory walls. Each frame undergoes a thorough inspection before moving to the next phase.
2. Sanding Zone
The unpainted frame, usually made of carbon, goes to the sanding area. Carbon is a porous material and must be carefully prepared before the paint can be applied. Our employees sand the frame by hand to remove the rough layer. Recently, we have started using water to reduce dust and make the process even more precise. This intensive process ensures that the paint adheres optimally and does not peel or chip. The precision of this manual work is crucial to guaranteeing the quality and durability of the final product.
3. Paint Shop
In the paint shop, the frame receives a base coat, depending on the chosen design and colors. Then, multiple options are available. The simplest process is decals, where we apply a sticker or transfer to the frame and then remove it. Another option is masking, carefully covering parts of the frame to create sharp edges, separated colors, and to prevent unwanted paint on specific areas. After this, the frame returns to the painters for the next round until the design is perfect.
4. Drying Room
The bike moves to the drying room, where it dries naturally. Fun fact: not every color dries at the same speed. Generally, lighter colors dry faster because they contain less pigment and have a higher percentage of solvents or binders. Metallic paints also tend to dry faster on the surface because their reflective properties enhance heat absorption. Want your bike to be ready even faster? Then ordering an Eddy Merckx in pastel colors might be a good idea.
5. Varnish Booth
Once completely dry, the frame goes to the varnish booth. Here, we apply two transparent lacquer layers. These varnish layers protect the frame from minor impacts, such as small stones or weather conditions. While no varnish is entirely impenetrable, any paint damage covered by our responsibility naturally falls under warranty.
6. Order Picking of Components
After the painting process, we start the logistics process, beginning with component picking. Ideally, we have all parts in stock, but due to the extensive range and frequent updates from suppliers, there may occasionally be some waiting time. A goods lift transports the components along with the frame to the assembly line, where everything is prepared for the next step.
7. Pre-assembly
During pre-assembly, we install essential parts such as the stem, cockpit, and shifters, as well as the wheelsets. These repetitive tasks are carried out in collaboration with Bewel, a social enterprise, emphasizing our commitment to social responsibility. Each step is executed with great precision to ensure consistency and quality.
8. Final Assembly
In the final assembly, all components are brought together to create a complete bicycle. Our experienced technicians ensure that all parts are fully functional. Once the assembly is complete, the bike is ready to be shipped to the dealer. The dealers take care of the final adjustments and deliver the bike in perfect condition to the customer, including tailored service. With passion and craftsmanship, we build every Eddy Merckx Bike. From configurator to dealer, the entire process is centered around quality, innovation, and customer satisfaction. Your dream bike is the result of an integrated and carefully planned process.