Material Production in Cycling

Material production in professional cycling has significant environmental impacts. From the manufacturing of carbon frames to aluminum components and synthetic tires – every aspect of modern racing bike production leaves an ecological footprint. This article highlights the environmentally relevant aspects of material production and shows paths to more sustainable alternatives.

Frame Materials and Their Environmental Impact

The choice of frame material has the greatest impact on the ecological footprint of a racing bike. Modern professional teams primarily use three materials, each with different environmental impacts.

Carbon Fiber Production

Carbon is the dominant material in professional cycling. However, the production of carbon fibers is extremely energy-intensive and causes significant CO2 emissions.

The production process of carbon includes:

1. Polyacrylonitrile (PAN) production – raw material from petroleum with high energy requirements
2. Oxidation – heating to 200-300°C over several hours
3. Carbonization – heating to 1,000-1,600°C in an inert atmosphere
4. Surface treatment – chemical activation for better adhesion
5. Resin infiltration – embedding in epoxy resin (also petroleum-based)
6. Curing – further energy-intensive heating

Aluminum Production

Primary aluminum production is carried out through bauxite mining and electrolytic reduction, which requires enormous amounts of energy. However, recycled aluminum offers a significantly more environmentally friendly alternative.

Advantages of recycled aluminum:

• 95% less energy than primary aluminum
• Almost infinitely recyclable without quality loss
• Established recycling infrastructure already available
• Lower costs for manufacturers

Steel and Alternative Materials

Traditional chromoly steel is experiencing a renaissance among environmentally conscious bicycle manufacturers. Although heavier than carbon or aluminum, steel scores with:

• Durability (frames often last 30-50 years)
• Repairability (can be welded and restored)
• Low production emissions compared to carbon
• Complete recyclability

Component Production

In addition to the frame, all other components also contribute to the ecological footprint. A modern racing bike consists of over 200 individual parts that are manufactured in various production processes.

Groupsets and Mechanics

Modern electronic groupsets such as Shimano Di2 or SRAM eTap contain rare earth elements and plastics whose production is environmentally harmful.

Material composition of an electronic groupset:

• Aluminum alloys (shifters, derailleurs) – 60%
• Carbon reinforcements – 15%
• Electronic components (lithium batteries, chips) – 10%
• Plastics – 10%
• Cables and wiring – 5%

Wheels and Tires

Wheel production combines various materials with different environmental impacts.

Production Locations and Supply Chains

The global distribution of bicycle production leads to long transport routes and additional emissions.

Geographic Distribution of Production

Main production countries for cycling components:

1. Taiwan – 40% of global frame production (Giant, Merida)
2. China – 35% of component manufacturing (affordable parts, tires)
3. Japan – Premium groupsets (Shimano)
4. USA – High-end components (SRAM, smaller manufacturers)
5. Europe – Assembly and final inspection (special frames, luxury brands)

Transport Emissions

The global supply chain of a single professional racing bike causes significant transport emissions:

• Ship transport Asia-Europe: 0.5-1.2 kg CO2 per bicycle
• Truck transport within Europe: 0.3-0.8 kg CO2
• Air freight (express deliveries): 15-25 kg CO2 per bicycle
• Distribution to dealer: 0.2-0.5 kg CO2

Challenges in Carbon Recycling

Carbon fiber composites are considered one of the most problematic materials in terms of recycling. Unlike metals, carbon cannot simply be melted down and reused.

Current Recycling Methods

Three main approaches for carbon recycling:

1. Mechanical Recycling
   • Shredding into short fibers
   • Use as filler material in lower-quality products
   • Loss of 70-80% of original strength
   • Economically unattractive
2. Thermal Recycling (Pyrolysis)
   • Heating to 450-700°C for resin removal
   • Fibers retain 70-90% of their strength
   • High energy consumption (150-200 kWh/kg)
   • Not yet industrially established
3. Chemical Recycling (Solvolysis)
   • Dissolution of resin through solvents
   • Best fiber quality (90-95% strength retained)
   • Environmental issues from chemicals
   • Very expensive and energy-intensive

More Sustainable Alternatives and Innovations

The cycling industry is working on various approaches to reduce the ecological footprint.

Bio-based Composites

Some manufacturers are experimenting with natural fiber-reinforced plastics:

• Flax fiber composites – 75% lower CO2 emissions than carbon
• Bamboo frames – renewable raw material, but structural limitations
• Hemp composites – promising for non-professional applications

Limitations for professional use:

• Lower strength than carbon
• Higher weight
• Unpredictable material properties
• Not yet UCI-approved for competitions

Cradle-to-Cradle Concepts

Innovative manufacturers are developing frame designs that are designed for recycling from the start:

• Modular construction (replaceable components)
• Mono-material constructions (only one material for easier recycling)
• Repairable connection points
• Leasing models instead of sale (manufacturer retains ownership and recycles at end of life)

Local Production

Smaller manufacturers rely on regional production to reduce transport emissions:

Advantages of local manufacturing:

• Shorter transport routes (up to 95% less transport CO2)
• Better quality control
• Support for local economy
• More transparent supply chains

Disadvantages:

• Higher production costs (2-3x more expensive)
• Limited scalability
• Less material selection

Comparison: Material Production vs. Usage Phase

An interesting perspective is the comparison between production emissions and emissions during the usage phase of a racing bike.

Measures for Professional Teams

Professional cycling teams can reduce their ecological footprint through conscious material decisions.

Checklist for Sustainable Material Procurement

• Preference for manufacturers with transparent sustainability reports
• Extension of equipment usage period (training bikes 2-3 years instead of 1 year)
• Reuse of components when changing frames
• Donation of decommissioned bikes to youth programs
• Agreeing take-back programs with manufacturers
• Preference for recycled materials where possible
• Documentation and offset of unavoidable emissions
• Collaboration with universities for recycling research

Examples from the Professional Peloton

EF Education-EasyPost (pioneer team for sustainability):

• Use of frames made from 50% recycled carbon (experimental)
• Partnerships with local recycling companies
• Tracking of entire equipment footprint
• Goal: Climate-positive by 2030

INEOS Grenadiers:

• Investments in carbon recycling research
• Lifespan extension of training bikes
• Systematic component recycling

The Role of the Bicycle Industry

The major manufacturers have the key role in reducing the ecological footprint of material production.

Current Industry Initiatives

Giant Manufacturing (world's largest bicycle manufacturer):

• Transition to 100% renewable energy in production by 2030
• Development of recyclable carbon systems
• Reduction of packaging materials by 40%

Shimano:

• Recycling program for old groupsets
• Reduction of rare earth elements in electronic components
• Research into bio-based lubricants

Trek/Specialized:

• Project One Certified Program (carbon-neutral custom bikes)
• Take-back programs in all stores
• Investments in cradle-to-cradle designs

Future Perspectives

Material production in cycling is facing fundamental changes.

Technological Developments by 2030

Realistic expectations:

• Recycling share for carbon increases to 15-25%
• Bio-based resins replace 30-40% of petroleum-based epoxies
• Additive manufacturing (3D printing) reduces material waste by 60%
• Blockchain-based material tracking for complete transparency
• Modular designs become standard for premium manufacturers

Long-term vision (2030-2040):

• Fully recyclable carbon composites as standard
• Local micro-factories with 3D printing technology
• Biodegradable temporary components
• Circular economy models with manufacturer ownership

Comparison with Other Industries

Cycling performs differently compared to other sports:

Recommendations for Action

For Manufacturers

• Investment in recycling infrastructure
• Transparent sustainability reports
• Implement design-for-recycling principles
• Establish take-back programs

For Teams and Athletes

• Longer usage cycles for equipment
• Systematic component recycling
• Preference for sustainable manufacturers
• Public communication about sustainability measures

For Consumers

• Quality over quantity (buy durable bikes)
• Use second-hand market
• Repair instead of discard
• Support manufacturers with sustainability commitment