Bikepacking Sleeping Bags: Sleep Like a Mummy
There are some things to consider when buying a sleeping bag. Low weight, comfortable temperature, synthetic fibres or down. An overview of sleeping bags.
On the Road with bc: The ORTLIEB Factory Tour. Overnighter included.
Andi visited the bicycle bag specialist ORTLIEB in Heilsbronn. A factory tour and a bike overnighter were on the agenda.
Made in Germany. 100 % waterproof. 5 year warranty on all products. These form the foundation of the ORTLIEB brand. We were able to get an inside look at the production facility at the company headquarters in Heilsbronn, near Nuremberg. We also got to explore the Franconian countryside by bike...
There he was, with his bike and his belongings, on the British roadside in British weather, with wet clothes in his bags: Hartmut Ortlieb on a cycling trip through England. In retrospect, it was lucky that Hartmut had such a hard time...
Forty years have passed since then, and the typical British weather of that time has set the ball rolling in multiple ways: Hartmut realized, while standing in the rain with giant trucks driving past him, that PVC tarpaulins like those used by those vehicles were a first-class idea for bike bags and panniers. After all, their contents remained dry thanks to the robust plastic covering, even in the heaviest precipitation. That was the birth of ORTLIEB, and in all these years, one characteristic of the company’s products has not changed: they are 100% waterproof.
But as constantly as the bags from Heilsbronn defy the harshness of nature, not everything in the industry has evolved:
taking a bike trip is now referred to as bikepacking. Gravel bikes turned out to be the perfect vehicles for this. And what of the brand ORTLIEB?
During our visit to ORTLIEB in Heilsbronn, we learned exciting insights and rounded off the day with an overnight excursion.
It all started with this sewing machine: once belonging to Mama Ortlieb, Hartmut Ortlieb used it to sew his first bags.
After starting in the rain, where is ORTLIEB today?
Ortlieb celebrates its 40th birthday in 2022. Since 1982, it has had a truly impressive career: the company has continued to grow at a constant pace. Today, the brand employs over 300 workers and their product portfolio has steadily expanded. Throughout the years, ORTLIEB has never tired of advancing into new segments or creating ones themselves through new innovations. The brand’s number-one promise – 100 % waterproof – combined with high-quality manufacturing, their "Made in Germany" ethos and the incredible longevity of all products (including a five-year manufacturer's guarantee) is still considered the key to their success. You can really feel this when you visit ORTLIEB's headquarters, especially in the service department.
Defective products do not have to be completely replaced at ORTLIEB . They can often be repaired. Andi tries his hand at repairing a pannier...
...but then hands it over to an experienced ORTLIEB employee.
ORTLIEB extends the lifetime of used products – and keeps their fans happy
The service department is ORTLIEB's hub for maintaining customer relationships: here, employees work to extend the life of all kinds of bags bearing the ORTLIEB logo. From patching small and large holes after a fall, to replacing broken attachment pieces or upgrading to a new attachment system, reparability is key to product development at ORTLIEB. It creates an almost indestructible connection between the brand and the users of its products: whether it's a classic Back Roller pannier or a state-of-the-art saddle bag, ORTLIEB customers want to continue using their bags even after they’ve been damaged, without any loss of quality. Many bags also carry the memories of their owners – of adventurous bikepacking tours, perhaps while riding in the rain in England.
By the way, you can also order many spare parts directly from our shop – at least ones that you can use to make DIY repairs.
ORTLIEB checks material mechanically for any weak points. To do this, the material is repeatedly bent back and forth.
ORTLIEB uses this machine to test the tear strength of the material. Here, the welded seam of two PVC strips lying on top of each other is being tested.
Welding instead of sewing: This is how waterproof works!
Speaking of indestructible: A key to ORTLIEB's consistently waterproof and durable qualities lies in the construction of their bags. In Heilsbronn, there is no sewing and then taping, which you might be familiar with from raincoats. In the production of ORTLIEB bags, PVC layers are welded in a specially-developed, high-frequency process. Of course it’s not comparable to a bicycle frame's construction, but this production method makes a difference, and is the(!) big trade secret at ORTLIEB. For this reason, Hartmut is highly selective when inviting guests to get a glimpse into the production halls in Heilsbronn. Generally speaking, it's a matter of insight: although the story of his founding and consequent success is worth telling, Hartmut Ortlieb prefers to stay out of the public eye. But he's not exactly the type to hide, either: if you visit Heilsbronn, it’s very likely that you’ll suddenly run into him, and he’ll seize the opportunity to strike up a casual-yet-technical conversation with you.
Photographs were still allowed when cutting the PVC tarpaulins, but unfortunately we cannot provide you with any images of the subsequent production processes. © bc GmbH
Genius or nerd? Or both?
On closer inspection, there is a lot to value in the company’s nerdiness: At ORTLIEB, they almost never fall back on existing technologies or standards, simply because they cannot guarantee the quality of the bags in every respect. Instead, ORTLIEB designs and builds the tools for bag production itself according to their own ideas – and the raw materials and components of ORTLIEB products aren’t just off-the-shelf, either. One example: Hartmut Ortlieb was not satisfied with available waterproof zippers at the time, so he founded another company to produce ones that met his standards. Incidentally, this makes him the world’s industry leader for waterproof zippers, and he can absolutely ensure that the closures on ORTLIEB products live up to the brand’s promise.
This is where ORTLIEB products are manufactured. There are different stations within the production line, such as sewing and assembly.
They are then prepared for further transport.
Where is ORTLIEB heading in the future?
As a long-standing partner of ORTLIEB, we have already been able to establish and develop a deep relationship with the brand in our day-to-day business. This is why it didn't take much persuasion to get us to look behind the scenes at the bag specialist. It took even less to get us to do a little round of bikepacking at the end of our visit. Our micro-adventure took us through a leisurely stretch in Franconia, to a small bivy sack and barbecue hut on the edge of the forest. Where will Ortlieb's journey lead in the future? Clearly, adventures on two wheels will continue to play a central role, in all types of weather. Exciting new products with clever features for bikepacking await us – all waterproof, of course!
Find out what else you need to consider when shopping for bikepacking bags in our guide.
The crowning glory of our visit to ORTLIEB: an overnight trip...
... including a cosy campfire and fantastic snacks and drinks.
After the requisite morning caffeine boost...
... we head back to ORTLIEB by bike.
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