June 4, 2020 - (Thaon-Les-Vogues, FRA) Born amidst the natural beauty of the Les Vogues region of France, Moustache Bikes has grown to become one of the largest e-bike manufacturing companies in the world. Their somewhat remote location was chosen for its great quality of life, amazing terrain to test their bikes, and affordability to attract a strong workforce.
Founded in 2011 by Emmanuel Antonot and Gregory Sand, the company experienced fast early growth. Two of their first challenges were to secure a frame builder and electric motor supplier, a tough sell for a new company with their initial small order. Drawing on previous industry relationships, and a slick sales pitch, Moustache not only acquired a top Taiwanese frame builder, but also landed Bosch motors.
In their first year of business they started with five urban models and forecast 500 e-bike sales. Much to their surprise they ended up reaching 1,200 e-bikes in their inaugural season. Their 2,000 square metre factory had a production capacity of only 120 bikes per day, and it was quickly apparent that more space would be needed soon.
In 2018 they purchased a new 10,000 square metre warehouse, which previously operated as a car parts manufacturer that was going out of business. Moustache not only acquired the new space but was also able to employ many of the car parts manufacturer’s now out-of-work employees.
The new factory currently has 110 employees with two assembly shifts running per day. They have developed an organized, systematic, quality-controlled environment to ensure their products are assembled and delivered in pristine condition.
Each e-bike is computer tracked from when it enters the facility until it leaves. Assembly technicians use a system called “pick to light” which uses lights to indicate the parts needed for each specific build.
Special e-bike lifts and uniquely designed assembly bays are testimony to their well thought out strategy to ensure employee comfort is an important part of the system.
Once the e-bike assembly is complete, the bikes are then re-checked for perfection before being wrapped in a special blanket and packed into the same box the frame and parts came in from Taiwan.
Moustache has a current capacity of 200 bikes per day which will increase once they complete another assembly line. For 2020 the company is expecting to sell 42,000 units and predicts an increase to 53,000 units in 2021. They are one of the few companies to offer a full line of e-bikes which includes urban, mountain, trekking, kids and tandem. They’re also in the process of adding an e-cargo bike line.
“With our focus only on electric bicycles, we have been able to address the specific needs of each e-bike model. We are constantly designing, engineering and testing our products to ensure the best possible quality. One of our current projects is designing an eMTB rear shock which addresses the ride qualities of an e-bike. Currently there is nothing available on the market,” explains Clément Bonneau, Global PR – Marketing.
“The current facility has a total capacity to produce 100,000 bikes a year. If we keep growing at our current pace, we will outgrow this facility in four years,” adds Clément – see full interview below.
In 2018 the Moustache Saturday 27 Trail 8 won the electric mountain bike of the year by Vélo Vert Magazine, one of the leading cycling publications in France.
The Moustache e-Team, launched in 2019 to compete at national and international eMTB events, is composed of Olivier Giordanengo, Jérôme Gilloux and Kenny Muller. Legendary, multi-decorated UCI World Cup mountain-biker and double Olympic gold medalist, Julien Absalon, races on a Moustache as well with his “Absolute Absalon” team.
Gilloux, 25, won the French eMTB XC Championship over Absalon. He took home silver at inaugural eMTB Worlds at Mont-Sainte-Anne last year as well, with Absalon taking third. The team rides the Samedi 27 Trail and Samedi 29 Game e-bikes.
Several years ago Moustache partnered with Quebec-based D’Amour Bicycle and Sport to be their Canadian and U.S. distributor. As e-bike sales started to take off around the world and the brand grew globally, their North American national sales manager, Stephane Cyr, has been spearheading Moustache’s growth starting in Canada.
Currently with 45 dealers across Canada, and the fast pace of global popularity, Moustache Bikes might be destined for another move sooner than later. For more information please visit here.
