BikeE

BikeE Corporation is revolutionizing the bicycle business, and powder coating is helping make it possible. The Corvallis, Oregon company is the world's largest manufacturer of "recumbent" bicycles. Recumbents allow the rider to lean back in a chair-like seat with the handlebars within easy reach. They are much more comfortable, especially for older riders than conventional bikes, which force riders to sit straight up on a hard, narrow seat, then hunch over to reach the handlebars. As the country's population continues to age, the recumbent bicycle addresses two increasingly important concerns: the aching backs of the baby boomer generation and the need for a fitness-conscious and ecologically-friendly way to commute to work and get exercise. Although recumbents now account for only about 1% of the bicycle market, the share is growing, and is BikeE is leading the way. They now produce half the recumbents sold, far ahead of the nearest competitor.

The company has been using powder coating since its start in 1993, when it was the brain child of two bike-loving engineers and little more than a machine shop operation. The two engineers wanted to produce a bike that was more comfortable, easier to ride, and more fun than standard bikes, conventional or recumbent. It's clear they found the right formula. The company's annual sales have doubled every year since it was founded. The company now employs 22 people full time and brings on additional workers to meet times of peak demand. With 800 dealers, BikeE boasts a dealer within approximately fifty miles of anybody in the country. Two years ago BikeE added a manufacturing plant in Taiwan to its U.S. facilities to help meet the rising orders for their products. Last year its manufacturing grew four-fold.

"While the bicycle industry as a whole is in a slump, we keep expanding," says Lee Eckroth, the product marketing manager at BikeE.

At its U. S. plant BikeE parts prior to assembly. It sends out every part for powder coating except the frames: handle bars, forks, chain stays, etc. Even the Taiwan manufacturing plant, which had been using liquid paint for twenty years, has recently installed powder coating capabilities to meet the needs of BikeE and its products.

Powder coating meet BikeE's needs in several major ways. It provides longevity. "We have seen very little fatigue of the powder coating," Eckroth says. "The bikes are exposed to the environment every day for six to seven years, and they look the same as they did on day one." The engineers at BikeE find powder coating simple and fast to use, helping increase productivity, which has played a major role in BikeE's success.

BikeE is also committed to powder coating, because it supports the overall company mission and culture. "Bikes are environmentally friendly product. We try to stick with that environmentalism into everything we do at BikeE," says Eckroth. "We recycle everything in our facility, boxes, aluminum, steel. We try to have the same philosophy when it comes to our processes, especially when that process wastes less. Powder coating is simply a very environmentally friendly application."

Powder coating has also allowed BikeE to keep pace with the soaring demand for its bikes. Continental Coating has been BikeE's powder coater for over six years "They have been fabulous," says Eckroth. "They were great when we were struggling and they've been great when we've been growing. He added, "They can turn around a product in 24 to 48 hours, so we are never down. That eliminates the fear of production stopping. They have been growing with us. It is a good working relationship."

Mitch Behrens, the President of Continental Coating Inc., also says the communications between the two firms help produce a superior product. "It has been a rewarding partnership," he explains. " Continental developed a strict quality assurance program exclusively for BikeE. Whenever they have a rush order or need prototype for a trade show, we accommodate them. The normal turn-around is closer to a week."

The future looks very promising for BikeE. As its slogan declares, the company does really appear to be "the next step in the evolutionary cycle."