Manufactures bicycles and e-bikes with aluminium and carbon frames at its St. Ingbert plant in Saarland.
KETTLER Alu-Rad GmbH
Cologne · St. IngbertNew on Amplifa
About KETTLER Alu-Rad
KETTLER Alu-Rad GmbH manufactures tens of thousands of bicycles and e-bikes per year with aluminium and carbon frames at its St. Ingbert site in Saarland. The company was formed in 2015 when ZEG took over the bicycle division of Heinz Kettler GmbH & Co. KG; the tradition of aluminium bicycle manufacturing dates back to 1977, when the Kettler Alu-Rad 2600 was presented – one of the first aluminium bicycles to be welded in large-scale series production. Manufacturing encompasses development, manual assembly, in-house painting, and technical quality inspections on modern production lines. The portfolio ranges from trekking and city bikes to e-ATB, gravel and cargo bikes, and speed pedelecs. Products are distributed via the specialist bicycle retail trade in several European countries.
- Site
- Köln
- Processes
- Bicycle and e-bike assembly (manual work), Painting (in-house painting of the bikes), Quality inspections / technical acceptance, Development and engineering of bicycles and e-bikes, Aluminium bicycle manufacturing (welded aluminium tubes in large-scale series), Bicycle and e-bike production (manual work, in-house painting, quality inspections), Frame size consultation, Frame consultation
- Materials
- Aluminium, Carbon, Assembly (Manual Work), Painting
- Founded
- 2015 (GmbH
- Industries
- Bicycle manufacturing, E-bikes/Pedelecs, Specialist bicycle retail
- 01
Engineering/Development
- 02
Assembly (Manual Work)
- 03
Painting
- 04
Quality Inspections/Technical Acceptance
- 05
Distribution via Specialist Bicycle Retail
Materials and Processes
Aluminium
Frame material for welded bicycle frames, the company's traditional lightweight-construction focus.
Carbon
Frame material for premium bicycle models.
Assembly (Manual Work)
Bicycles and e-bikes are predominantly built through complete manual assembly.
Painting
In-house painting of the bicycles at the plant.
Locations
St. Ingbert
DEProduction plant
- Materials
- Aluminium, Carbon
- Modern production lines
Cologne
DEHeadquarters/Registered office
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Bicycle and e-bike assembly (manual work)Assembly | – | – | – | tens of thousands of bicycles/e-bikes | Aluminium, Carbon |
| Painting (in-house painting of the bikes)Surface treatment | – | – | – | – | Aluminium, Carbon |
| Quality inspections / technical acceptanceInspection | – | – | – | – | – |
| Development and engineering of bicycles and e-bikesEngineering | – | – | – | – | Aluminium, Carbon |
| Aluminium bicycle manufacturing (welded aluminium tubes in large-scale series)Joining | – | – | – | – | Aluminium |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Production lines (modern manufacturing) | – | – | – | – | St. Ingbert, Saarland |
Additional services
Reference customers
History
- 1949
Heinz Kettler founds the company in Parsit (Ense), the original headquarters of the Kettler Group (Wikipedia)
- 1977
Presentation of the Kettler Alu-Rad 2600 – one of the first aluminium bicycles in the world to be welded in large-scale series production (Wikipedia)
- 1978
KETTLER Alu-Rad, since 1978 a pioneer of 'Made in Germany' lightweight bicycle construction; development of the first aluminium bike (company website)
- 2015
Insolvency of Heinz Kettler GmbH & Co. KG; ZEG takes over the bicycle division and founds KETTLER Alu-Rad GmbH, based in Cologne, continuing the bicycle plant in Saarland with 80 employees at the time (Wikipedia)
- 2024
Report in the WE+BIKE magazine (issue 10, May 2024) on the St. Ingbert plant as one of the most modern and largest bicycle plants in Europe