Frog bikes release annual emissions report for 2023

Frog Bikes has released its emissions report for 2023. The report focuses on the company’s pursuit of reducing emissions and efforts to increase sustainability, with aluminium and cardboard consumption being focus areas for the company.

The report found that 93kg of CO2 emissions were produced per bike, with 92% of emissions coming from raw materials and components. Inbound logistics made up 1%, factories, travelling and head offices made up 4%, and outbound logistics made up 3%.

Material breakdowns show that Aluminum led the way, being 81% of emissions. Steel, plastic, and cardboard and paper made up 5% of emissions. Rubber made up 4% and others made up 1% of total emissions.

Since 2019, the company has seen a 53% reduction in internal emissions per bike, as well as a 23% reduction in emissions per bike.

The road map to aluminium recycling

Starting in 2018, the company set out its strategy to increase the recycling of aluminium. Internal examinations of Frog bikes environment took place between 2018 to 2019, finding that aluminium was the company’s biggest challenge.

The search for new providers began in 2020, looking for suppliers that could integrate recycled aluminium into production. This took time as finding the right partners and clearing common myths proved time-consuming.

Sources of lower-emission aluminium were found in 2021, but the suppliers were unable to handle frame production and painting. This proved a challenge to the company.

A supplier was found in 2022 that could produce frames and forks using 25% post-consumer recycled aluminium. The only problem was that significant funding was required for an upfront order.

Testing and certification took place in 2023 to ensure the new frames were up to standard. The new frames were even stronger than the existing ones, exceeding expectations. Third-party certification was granted confirming recycled content and helping attain a green loan from the Development Bank of Wales to help with the upfront order.

The frames arrived in 2024, with production to start this year on Frog bikes best sellers. More models will follow on from these developments.

Investment in a cardboard crinkling machine increases sustainability and environmentally friendly efforts. The machine turns cardboard packaging into protective cushioning material, protecting bikes on delivery to customers.

Reusing cardboard cuts down on waste and reduces the need for new materials. This is because the cardboard boxes that are used by suppliers to  ship other materials to Frog bike are used in this process.