Magura - German manufacturing on the world's trails
For 20 years, Magura has produced top quality disc brakes in Germany. We had the chance to take a look behind the scenes.
For 20 years, Magura has produced top quality disc brakes in Germany. The perfect reason for us to take a look behind the scenes of one of the most successful bicycle brake manufacturers in the world.
In 1893, Gustav Magenwirth founded the Gustav Magenwirth GmbH and Co. KG under the brand name of Magura (MAGenwirth URAch) in Bad Urach, in the south of Germany. Magura started out producing juice presses and in 1922, they began producing bicycle parts. The Bad Urach production site is made up of three locations including the injection moulding factory in Hülben, a neighbouring town and the brake assembly line located in the next neighbouring town of Hengen.
Plastics Technology Facility, Hülben
Other than brake levers and housings for Magura’s own products, parts are also produced for notable industry customers. 45 injection moulding machines run 24/7 and according to executive director Udo, “A lot of know-how is hidden in our injection moulding machines. We do not want to give this away.” The machines can produce parts with a range of sizes from 1 mm to a DIN A4 sheet of paper. In some cases, the moulds weigh up to 1.5 t due to the 2000 Nm of force that they have to endure.
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Magura’s expertise in injection moulding technology has made them specialists. The last ten years has seen a doubling of the number of moulds they have available.
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Injection moulding at its best
Next to where brake parts are constructed, there is the another set of highly specialized injection moulding machines, showing Magura’s competence in this area once again. As mentioned before, Magura does not just work with brake components, but produces a multitude of other products such as forks for wheelchairs. Multiple types of material can be used, and the machines are so precise that even threads do not have to be retouched; they are ready for assembly.
When it comes to the brakes, all the finished parts are moved from Hülben to Hengen to continue the construction process.
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Brake Production Facility, Hengen
Only 6 miles away and opened in 2011, the brake components are split into eight different production lines for final assembly. All HS, MT7 and MT8 brakes are finished here and prepared for shipping.
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Besides bicycle brakes, Magura builds brakes and clutches for motorcycles as well. Manufactures like BMW, KTM, Ducati, and Husqvarna have deepened on Magura’s high-quality parts for years. Made in Germany is more than just an empty saying here. An overwhelming majority of Magura parts are produced in Germany.
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Quality standards
To keep the facilities clean and free from dust and dirt, the room is pressurized so that when you open a door, air rushes out instead of in. Even the blue crates you see in the above and below pictures, which are used to transport parts within the factory, are cleaned with an oversized washing machine.
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“We, meaning Magura, place much value on quality control and are responsible for optimizing and monitoring our processes.” Manuel, Factory Manager
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To round this up, we would like to thank the entire Magura team for taking the time to show us around. We learned a lot and we wish you best. Thanks!
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