Recycled aluminium investment helps Frog Bikes cut carbon footprint

Children’s bicycle manufacturer Frog Bikes is taking a step towards lower-carbon production as it has secured GBP 150,000 (USD 201,000) in funding to support the use of recycled aluminium in its frames and forks. The loan has been provided through the Development Bank of Wales’ Green Business Loan Scheme and will enable the company to reduce emissions associated with each bike it produces. By incorporating aluminium that contains 25 per cent post-consumer recycled content, Frog Bikes expects to cut carbon emissions by around 5.8 per cent per bicycle. The change is estimated to save approximately 3.5 kilograms of CO₂ for every kilogram of aluminium used, equating to roughly 5.8 kilograms of CO₂ per bike. Testing carried out by independent specialists found that the recycled aluminium matches the strength and durability of newly produced material, encouraging the company to look at further reductions going forward.

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Frog Bikes believes this is going to be a novel initiative towards the use of fully recycled aluminium across its product range. If achieved, this could deliver emissions savings of up to 864 tonnes of CO₂ equivalent each year, comparable to removing around 375 cars from the road annually.

Founded in 2013 by Jerry and Shelley Lawson, Frog Bikes was born out of the founders’ frustration at the lack of lightweight, well-designed bicycles for children. Working alongside Brunel University and bicycle engineer Dimitris Katsanis, the company helped challenge conventional approaches to children’s bike design, emphasising weight, ergonomics and performance.

The business now operates from a 120,000 square foot manufacturing facility at Mamhilad Park Estate near Pontypool, employing 35 people. Holding a production capacity of  400,000 bikes a year, Frog Bikes’ growth has been recognised with the King’s Award for Enterprise.

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On the sustainability front, Frog Bikes, a member of the SME Climate Hub, has pledged to cut its emissions by half by 2030 under the United Nations’ Race to Zero campaign, aligning its operations with wider global climate goals.

Chief Frog Jerry Lawson said the company has been steadily embedding environmental thinking across the business. He noted that progress has already been made through the removal of single-use plastics from packaging, more efficient bike designs that use fewer materials, and the adoption of renewable energy at both factory and office locations.

He added that switching to recycled aluminium represents one of the most significant opportunities to further lower emissions per bike, but acknowledged that external support is needed to move at speed. The funding from the Development Bank, he said, allows Frog Bikes to advance plans that would otherwise take much longer, while supporting the company’s broader aim of encouraging healthy, active lifestyles among children.

David Knight, Investment Executive at the Development Bank of Wales, said Frog Bikes had already demonstrated strong progress on its journey towards net zero, while recognising the need for continued improvement. 

Funded by the Welsh Government, the Green Business Loan Scheme offers financial support to businesses undertaking projects focused on energy efficiency and carbon reduction. Funding is available from GBP 1,000 ( USD 1,300) up to GBP 1.5 million ( USD 2.0 million), with discounted interest rates and long-term capital. Beyond lending, the scheme also provides access to consultancy assistance, either fully or part-funded, such as bespoke energy audits tailored to individual business needs.

Applications are open to Wales-based limited companies, sole traders and partnerships that have been trading for a minimum of two years and have filed at least one full set of annual accounts.