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Orbea ‘(r)evolutionizes’ facilities in northern Spain

Orbea facility in Mallabia

Spanish cycling giant Orbea is getting set to ‘(r)evolutionize facilities in Mallabia [northern Spain], making them more effective, more innovative and more competitive’.

“Our goal is ambitious: to become the leading brand in the world of cycling in the area of product customization,” said Miguel Ángel Estandía, Orbea’s Industrial Director. “As bicycle manufacturers, we need facilities that enable us to be more efficient and better along the entire production chain, with one single goal in mind: to offer more and better solutions, and to do it faster.”

Orbea has set out a number of activities set to take place, leading up to summer 2018…

Evolution of the painting area
This is the preliminary step for the start of the project to upgrade the facilities in Mallabia. According to Orbea, this is in order for the current production to remain unaffected by the construction of the new facilities.

“It is a very important moment in the project to prevent any impurities that are found in the environment from affecting the quality and finishing of our frames,” said Miguel Ángel. “This way, we get a new totally encapsulated area that, once the new painting facility is finished, we will use for prototype painting, colour and texture research and a whole series of innovations for which we need a specific area.

New frame painting area
The new painting facilities, which will be ready in October 2017, will be located in the southwest corner of the plant. Covering a total of 600 m2, “They will allow us to provide a faster, more efficient response to the growing demand for bikes personalized with MyO,” said Miguel Ángel.

This space will contain 9 separate areas:

  1. Frame selection area
  2. Sanding area
  3. Preliminary masking room
  4. Base colour painting room
  5. Masking room
  6. Colour room
  7. Decal application room
  8. Varnishing area
  9. Final control

Reorganization of the warehouse area
The Orbea warehouses will also undergo changes with the same goal in mind: efficiency. “By the end of 2017 we will be able to have more products in the same amount of space and thus, once again, be more efficient in the service we provide to users,” added Orbea’s industrial director.

New assembly area
In 2018, Orbea will undertake the renovation and redefinition of its three assembly lines, which will be ‘functioning full throttle as of the second quarter of next year’.

New testing area
Here, innovation is the other big objective of this project. “We want to surprise people with new and distinctive finishes on our frames, with imaginative solutions that improve the experience of our customers on their bicycles,” said Miguel Ángel.” To accomplish this, this (r)evolutionary project at Orbea will bring with it new spaces in which to research and test out our frames in even greater detail.”

Orbea is part of the Mondragón Cooperative Corporation and is Spain’s largest bicycle operator. Orbea bike frames are manufactured in Asia and finished in Spain – with the brand shipped worldwide.

In 2011, Orbea further cemented its relationship with Orca – the wetsuit and apparel tri brand. Heralding from New Zealand, Orca is part of the Orbea family – with Orbea and Orca reaching an agreement in 2011 for Spanish Orbea to acquire Orca’s ‘operation rights in the triathlon and compression area.’ This deal gave Orbea global rights to the Orca brand, following ‘four years of fruitful relations’ between the two companies.




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