Orbea was originally set up in the Basque village of Mallabia in 1840 as a weapons manufacturer and only started producing bicycles in the 1930s
The design of a new mountain bike can take many months. Mikel Bergara produces a 3D image of the bike before producing a plastic mould which can then be used to assess how well it works
Once a newly-designed bike has been thoroughly tested, the mountain bike is signed off and ready to be put into mass production
The separate components that make up a mountain bike are individually built in the Far East and assembled at this factory in the north of Spain
The bike frames are sprayed with a robot that has been carefully calibrated to cover every part of the frame with an even layer of paint
The final touches are applied by hand by some of the 200 strong army of workers that start at six o'clock in the morning
Once the frames have been painted, they join an assembly line where the rest of the bike's components are added
Orbea produce around 600 bikes a day and in 2009 their turnover was 60 million euros
At the end of the assembly line the bikes are carefully packaged, after all, some of these bikes retail for several thousand pounds
The bikes are packaged and then sent to their distributors throughout the world - places as far afield as Mexico, Japan and Singapore
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