Bicycle chains from Germany: A visit to the only German manufacturer

Despite modern high-tech bikes, the bicycle chain is considered indispensable, even though it is perceived as strong, heavy and greasy. Without it, even the strongest calves are useless, and maximum lung volume also plays a decisive role on bikes with derailleur gears. Yet the concept of the drivetrain has hardly changed for over 130 years. As early as 1885, the bicycle chain made it possible to develop a vehicle that could be ridden ergonomically and safely, starting with the penny-farthing. Kettenfabrik Wippermann jr. in Hagen has been producing bicycle chains since 1893, with tradition playing an important role. The company is now run by the fifth generation of the Wippermann family, although none of the bosses bear this name today. With over 130 years of experience, bicycle chains "made in Germany" are produced here - the only German bicycle chain manufacturers.

Bicycle chain: Born out of necessity

The founding story of Wippermann Jr. GmbH has an interesting origin: The son of the entrepreneur Wilhelm Wippermann constantly had problems with his bicycle chain, which kept breaking. It had to work better! At a time when industrialisation was on the rise in Germany, Wippermann Jr. laid the foundations in the southern Ruhr area for the production of a chain that would be more resistant than what was available on the market at the time. Looking back today, we can say that this was a far-sighted decision. The now uninhabited director's villa in the Wilhelminian style still stands on the extensive site. Now located at the very edge of the grounds, it was once the centre of the then much smaller site. Today it looks somewhat abandoned, surrounded by the functional industrial halls that have grown up around it over the years.

A large part of production here is focussed on industrial chains, a business area that was added in the 1960s. Dorette Schierling, who is responsible for marketing in this area, shows us a link of an industrial chain that probably weighs more than a complete bicycle chain. As we enter the production halls, we are impressed by the monotonous humming, but even more by the cracking and rumbling, often huge machines. Each of them, seemingly without any recognisable pattern for a layman, does its part on the way from a piece of steel to the finished bicycle chain. Marcel Stiens, 32 years old, is a developer and product manager for Wippermann Connex chains. He explains the production process to us.

From wire to lug and bolt

First, the raw outer and inner flaps are produced from millimetre-thin sheets. Similar to baking biscuits at Christmas, these so-called "eights" are punched out of the material by machines with a loud "pop" - but with a pressure of 180 tonnes. The rollers of the chain, i.e. the small barrels that later lie between the teeth of the sprocket, are produced in a similar way. They are punched out of a steel strip several millimetres thick and later rolled into a round shape. The raw material for the chain pin, which holds everything together, is then delivered as kilometres of steel wire on huge spindles.

After it has passed through a straightening machine that straightens the wire, it is cut to the required length. Later, the chain pin is given the characteristic conical notch at the ends. It is worth mentioning that almost all the raw materials come from the surrounding area: Metal processing is widespread in the Ruhr, Sauerland and Oberberg regions, which means that the distances to Wippermann are short.

Chain experts with secret know-how

What is not visible here are the intricacies of production. Of course, no manufacturer likes to be watched at work when it comes to their own recipes. This involves special curing processes, customised coatings and similar procedures. However, the essential elements are already available in their basic form: the roller, the inner and outer plates and the pin. Since the successful Sachs-Sedis derailleur chain in the seventies, the holes in the inner plates have been moulded into collars facing inwards. The roller later sits on these collars. As a result, it is flexible, which makes shifting chains flexible for shifting operations on the cassettes, in contrast to the rigid single chains. If you pick up a drivetrain for a hub gear system and one for a derailleur gear system, you will immediately notice the difference.

Each individual component of the chain is hardened. To do this, the individual parts are transported on a belt into an oven, which heats them to an impressive 900 degrees; they are then cooled in an oil bath and then "tempered" again, i.e. slightly heated. The flaps are then de-oiled in large barrel-shaped centrifuges. In a kind of washing machine, they are later given their smooth surface together with water and small abrasive particles. Incidentally, the expert explains: "Coatings are always a compromise." They are chosen when more corrosion protection is required, for example due to the specific requirements of the area of application. The taste of the customer, in this case the cyclist, certainly also plays a role. A strikingly brass-plated, i.e. gold-coloured chain looks more attractive. However, a coating always tends to reduce robustness somewhat - this must be weighed up.

The special chain link geometry

In terms of shape, manufacturers rely on special contours - especially for the outer plates. These are designed to make the chain particularly precise and easy to shift. In the high-quality Connex chains, these outer plates are called "Diamond Shape" and "Speed Wing". The "Power Pin", as the pin is called at Connex, is given its particular robustness by a special radial riveting process. In addition to hardening the surface, it also undergoes an additional tempering process. These processes are the result of many years of experience on the part of the manufacturer, but understandably, they do not like to be shown in detail. The relatively small machines work like mechanical wizards when they finally join the individual parts - especially when producing brass-plated, i.e. gold-coloured chains. The links and rollers sit on long mandrels on which they have previously threaded themselves in a kind of rotating bowl, and are then wiggled down part by part to form a valuable link in a 118-link chain.

The best-selling chains are the 11S0, 11SE and 11SX - the cheapest, the e-bike version and the most complex 11-speed chain from Connex. The latter have a stainless steel inner plate, which ensures maximum wear resistance.

Marathon chain not yet possible for the bike

The newly introduced 12-speed chain also runs well, especially for the single sprockets that are now very popular on gravel bikes. Rohloff riders also like to use the 8 SX chain. The product manager explains: "We have the advantage here that we can always transfer expertise from the industrial chain sector to bicycle chains." He mentions the dream of every cyclist: the "marathon chain". The speciality here is that this chain is largely self-lubricating. Its bushings contain lubricant that gradually leaks out at the desired points, significantly extending the service life of the chain.

Dorette Schierling, who is responsible for marketing industrial chains at Wippermann, explains: "When it comes to industrial chains, companies are already considering whether they should invest in a high-quality chain rather than a simple, inexpensive one. After all, if half the industrial plant has to be dismantled for maintenance or chain replacement, the costs quickly add up." So why not also produce a "marathon chain" for bicycles? However, the product manager explains that this would be difficult. "Foreign bodies end up where they shouldn't be. In the worst case, even sand or salt." The lateral flexibility of derailleur chains inevitably requires such gaps through which foreign bodies can penetrate.

Tough test conditions for the drive

In Wippermann's test laboratory, experience is gathered in tough conditions, whereby the company's own chains are compared with those of other manufacturers in defined test arrangements and times. They are tested for days under harsh conditions, such as the addition of sand, to ensure that they can withstand the requirements.

The conviction prevails here that the "made in Germany" chain manufactured in Hagen is one of the best on the market. A fixed service life cannot be guaranteed, as the service life of a chain depends on many factors, explains Marcel Stiens: "It is simply not realistic to come up with such figures." It is also important to note that the drivetrain must be considered as a system. A combination of a cassette from the entry-level quality range and a chain from the Connex high-end range would result in the cassette wearing out much faster than the chain. So it has to fit together.

When there are new drives on the market, product management and developers analyse the products and develop suitable chains if necessary. The Wippermann single sprockets, so-called narrow-width sprockets, have been developed for e-bike motor manufacturers, for example. The e-bike sector is also seeing growth in the chain sector. Stiens explains: "Anyone who buys an expensive e-bike also understands that the replacement chain has to be of a higher quality than on an old bike without a boost."

Around 35 per cent of the bicycle chains are exported, with a large proportion going to Europe, particularly the Netherlands and the UK. However, there are also sales offices and partner wholesalers in Lithuania, Malaysia, Thailand and the USA.

Wholesale instead of the Internet

Connex has been represented for many years wherever chains are put to the test. "We have service stations at around 30 German and international races and events," says the chain master. "BIKE Festival Willingen, Lake Garda, the one-day classics ..." There is important feedback from consumers, which is crucial for further development. This shows once again that one should not assume that a traditional company with firm, long-established values and ideas cannot also appear young, modern and open. Even if internally the - often very positive - values of a family business are formative. The company has already survived over 130 years with the "chain" concept, all made in Germany and with suppliers from the region.

Wippermann: Facts and figures

• Foundation: 1893 by Wilhelm Wippermann jr.
• Headquarters: Hagen-Delstern (southern Ruhr area)
• Number of employees: approx. 300, of which around 30 are in the bicycle chain area
• Floor space: approx. 47,000 square metres
• Products: Bicycle chains, 36 different models: 12-speed, 11-speed (best-seller), 10-speed, 9-speed, 8-speed, 7-speed, 1-speed chains and chainrings