Kalkhoff bicycle production is switching to low-temperature powder coatings, promising significant advances in energy efficiency. This innovative technology is now being used in the company’s ultra-modern paint shop in Emstek near Cloppenburg. Kalkhoff is thus underlining the quality claim of the “Made in Germany” label.
Paintwork plays a central role in bicycle production — it not only ensures visual appeal, but also provides essential protection for the bicycle frames. In order to offer customers the highest quality, the e-bikes are painted directly at the Kalkhoff plant in northern Germany. Only high-quality low-temperature powder coatings are now used as a primer.
“Our aim is to constantly improve. The switch to low-temperature powder coatings is a step in this direction,” explains Amelie Möller, Kalkhoff CSR Manager. “The lower temperature during curing means we can not only save energy, but also reduce costs — without compromising on quality.”
Technological benefits in detail
Low-temperature powder coatings consist of fine plastic particles, pigments and additives and cure at significantly lower temperatures than conventional powder coatings. For Kalkhoff, this means Instead of 180 degrees Celsius, curing takes place at just 160 degrees. This reduction brings considerable advantages in terms of energy consumption and reduces CO₂ emissions.
“The low-temperature powder offers the same high-quality technological properties as conventional powder. It protects against corrosion, ensures a glossy finish and is resistant to mechanical stress. The big difference lies in the increased energy efficiency, as less gas is required due to the lower temperatures.”
The resulting gas savings are equivalent to the annual energy consumption of several German households and mark a further step in Kalkhoff’s strategy to reduce greenhouse gas emissions.
A complex and well thought-out conversion process
The implementation of this new technology was a comprehensive process that took more than a year — from the initial idea to official integration into the production process. The first test runs began in summer 2023, and after promising results and intensive test phases, including external laboratory tests, the changeover was completed in late fall 2024.
