Exclusive Brainchild Tour | Part One | The Megapod

Summary

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Kitesurf365 – Brainchild Factory Exclusive Tour | Megapod Part One

Date: June 25, 2026
Host: Adrian Kerr
Guests: Ralph Grosel (Brainchild Founder/Designer), Arla Dieu

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Episode Overview

In this special episode of The Megapod, Adrian Kerr and Arla Dieu offer listeners a rare, behind-the-scenes audio tour of the new Brainchild factory in North Macedonia. Guided by Ralph Grosel, kiteboarding’s renowned innovator, the team explores everything from the facility’s advanced manufacturing processes and material innovations to company culture and expansion plans. This episode is rich with technical insight, playful banter, and candid reflections on the journey from humble beginnings to becoming a globally recognized kite producer.

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Key Discussion Points & Insights

1. Arrival and First Impressions ([00:00]–[06:00])

• Setting the Scene: Adrian and Arla arrive in cloudy North Macedonia, commenting on local bear signs and sustainable ambitions of Brainchild. They reminisce about their first visit, noting the company’s significant growth and reputation since.

  "Before a Brainchild guy had won King of the Air, before it had won two world championships back to back, and before it had tripled in size." – Adrian [01:13]

• Ralph Grosel welcomes them, mentioning he could use more sleep and less drama, yet is proud of the team’s achievements and excited to show off the new premises.

• Factory’s Expansion: The new factory is much larger, employing many more people and supporting further growth, with a land extension for possible future builds.

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2. The Brainchild Lab and Material Innovation ([05:53]–[09:37])

• The Proprietary Approach: Ralph explains Brainchild’s unique approach to material development, emphasizing the shift from using materials repurposed from other industries to designing kite-specific composites.

  "In the history of kitesurfing, there was literally never really a company dedicating making material specifically for the kitesurfing industry… We try to change that." – Ralph [06:24]

• Material Examples: Dacron, once a sail material, and canopy fabrics previously used for sailboat spinnakers, are being replaced with purposed innovations.

• Confidentiality and Growth: The lab has grown by 50% but not all areas can be shown for IP reasons. Ralph expresses joy at moving back into creative development thanks to a larger, specialized workforce.

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3. Team and Management Philosophy ([10:20]–[12:22])

• Automotive Expertise: Management staff, notably Svetlana, were recruited from North Macedonia’s largest automotive employer, Kromberg Kombuch, bringing transferable skills in large-scale production line setup.

• Entrepreneurial Challenge:

  "Running such a thing or creating such a thing itself is a huge achievement. And the building was made in eight months... including all the paperwork, this is just… like, I don't know even how they did it." – Ralph [12:12]

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4. Factory Workflow: From Raw Material to Finished Kite ([13:52]–[46:21])

Tour Highlights

• Scale and Structure ([13:52]–[17:43]):

  • The building is 3,500+ sqm, with logical layout for lean, scalable production. There's a focus on optimizing space and workflow for future growth.

• Raw Materials and Warehousing ([18:13]–[20:25]):

  • Custom materials make up €250K+ of inventory; nearly all are specified uniquely for Brainchild’s uses.

• Digital Printing & Calendaring ([21:12]–[24:09]):

  • Six proprietary printing machines, with one handling 181,000 sqm in two years. Colorization processes are largely in-house.

• Cutting and Quality Control ([26:01]–[29:47]):

  • Multiple custom lasers and oscillating knives cut 30+ material layers at once. Worker access is restricted to streamline focus.

  "Every worker has an access card so that the people are not like running around but being much more focused on what they actually have to do." – Ralph [27:45]

• Assembly Lines & Gender Dynamics ([29:42]–[32:09]):

  • Two parallel lines: canopy assembly and leading edge/struts. Most assembly staff are women (a regional industry trend), while men handle most cutting and mechanical roles.

• Technical Production & Innovation ([32:09]–[36:15]):

  • Detailed explanation of critical tolerances, such as how millimeter differences on leading edges can create twists and compromise quality.

  "A millimeter in difference on the leading edge is creating a distortion... and would result into a twist." – Ralph [32:48]

• Proprietary Construction Techniques ([34:36]–[35:20]):

  • Kites are both glued and stitched; sometimes pro welds are backed by additional stitching for reinforcement.

• Final Assembly & Inspection ([38:42]–[41:55]):

  • Over 100 finished kites inhabit the final assembly area.
  • Every kite is inflated twice for 24 hours for leak/symmetry checks.

  "No kite is leaving without these two checks." – Ralph [40:02]

Technical Highlights: Materials & Kites

• Materials Matter:

  • Different lines (e.g., Thrive Lite X, “Whisper”-class) use material as light as 32g/m².
  • Fine-tuned printing and colorization contribute to product identity and quality.

• Notable Gear Innovations ([42:09]–[44:09]):

  • F-One pulleys—unique looped system for extra safety and function.
  • Difference between fixed and pulley bridles explained, including minor, crucial movements in attachment points.

  "The pulley here never moves more than 2 centimeters... but that's completely enough." – Ralph [43:54]

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5. Packaging, Logistics, and the Brainchild Philosophy ([44:09]–end)

• Finishing Touches:

  • Kites are carefully folded and bagged—attention to detail preserves their ‘crispness.’
  • Material selection affects feel and sound (“Brainchild sound”—the signature crinkle).

• Logistics:

  • Weekly shipments go mainly to the Netherlands and France for distribution to brand partners (Ren, Harlem, F1).
  • Company strives to use recycled, high-quality European components for packaging.

• Company Culture & Regional Pride:

  • Most employees are local; company uses buses to ferry staff. Many join from the regional textile workforce.
  • Strong sense of accomplishment and national pride infuses the team.

  "I think Brainchild is extremely well known in this little country... the people are quite proud about what they're doing here, you know, like competing against the rest of the world." – Ralph [49:19]

• Ralph’s Reflections:

  • Emphasizes satisfaction in seeing ideas move from lab to large-scale production.
  • Now, with solid management, he can focus on innovation again.

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Memorable Quotes & Moments

• On Vision and Growth:

  "Whenever you have the chance to really plan things from A to Z, that… automatically you have a better product." – Ralph [12:32]

• On Local Hiring and Skilled Labor:

  "Most employees have a sewing background… I think it's the package. Always you have to create the right package for the people. And it seems that we can do that." – Ralph [49:44]

• On Pride and Process:

  "Knowing that the kite starts over there and in the end of that line, it's done… it's quite a nice journey." – Ralph [49:46]

• On Product Experience:

  "Brainchild products always smell good… such distinctive Brainchild sound. It's like a crinkle, isn't it?" – Adrian [39:21]

• On Innovation:

  "I can focus on the innovation again. So I can go back to the drawing board and hopefully come up with some cool new ideas." – Ralph [48:20]

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Notable Timestamps

• 00:00–03:36 – Arrival, anecdotes, and first impressions of the region and factory
• 05:53–09:37 – Material innovation philosophy, Brainchild’s unique R&D, lab location
• 10:20–12:22 – Management team background, production expansion
• 13:52–17:43 – Description of the production floor, scale, and workflow
• 18:13–20:25 – Raw material storage, unique material customization
• 21:12–24:09 – Printing and calendaring processes
• 29:42–32:09 – Assembly process, gender roles, and labor division
• 38:42–41:55 – Final assembly, QA, and inflation protocol
• 44:09–46:21 – Packaging, material specifics, shipment logistics
• 49:19–51:04 – Regional hiring, company pride, what sets Brainchild apart

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Conclusion

This episode offers a dynamic, insightful look at the inner workings of Brainchild—blending technical walkthroughs with human stories of growth, pride, and innovation. By the end, listeners gain a deep appreciation for the meticulousness, creativity, and spirit powering one of kiteboarding’s fastest-growing and most respected manufacturers.

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To explore part two and more Megapod adventures, subscribe and follow Kitesurf365!

Transcript

[A]

Welcome to North Macedonia, where it's turned out nice again. Actually, it's quite cloudy today, honestly. But we're in a car, so that's okay. Air conditioned, of course. We're cruising at 110km an hour. I got Arla Dieu next to me, big solar field to our right. Taking on the sustainable objectives of Brainchild production. Indeed, that is true. There's also a lot of signage about bears. We're yet to see one, but I like the sign where it looked like a pig was chasing a bear. And there was also another one where it looked like the bear was having a shit. And I think. Actually, I don't think that was graffiti. I think they really. They did have that. So that's great. We are 10 minutes away from pulling up at the Brainchild factory portrait. Visited Brainchild in its original premises. Before a Brainchild guy had won King of the Air, before it had won two world championships back to back, and before it had tripled in size. I think it's tripled in size. So it's now employing a lot of local people and making far, far more product than it was. I've also heard there's a special laboratory section which apparently Ralph has told us we might have time to go and see. As if that's not the bit that we're desperate. Can we just go there? So, yeah, there's quite a lot I want to learn and we're going to take you along for it. So what was the kite when you first showed up? What were they manufacturing? That was the thrive. And they just started to make a Reading kite. And that. That was unannounced. And I remember us seeing the Reading logo in there going, oh, so, yeah, that was quite exciting. I wonder what news we can break this time. But it's F1 read in Harlem. Those are the three. Yeah. And maybe some more. Who knows? Who knows? We're gonna find out. And. Yeah. All headed up, of course, by Ralph Grossel, who is Kai Boarding's most notorious kite designer. Every brand he works for, it seems to win the competitions and win the hearts of customers, too. So. Yeah, but this is a whole new challenge for him, you know, going from designing kites for brands to owning the factory that manufactures.

[B]

Right.

[A]

The kites is crazy. It's a crazy leap. And then scaling it. Exactly. And a talented entrepreneur, too, so it'll be cool to go pick his brains. All right. Doesn't look like we're driving into the dark cloud, which is good. Yeah, I think we're good. Yeah. Metaphorically. As well, hopefully. Good. Okay, you'll hear from us next as we pull up to the. To the new factory premises. Catastrophic equipment failure.

[B]

Going for the boogie loop double just to get the landing. Oh. Had a couple of strings and it was extremely dangerous. Guys, I sent the trap and it is gold for Ellie Aldridge and gold for Great Britain.

[A]

Okay, just coming up to the building now and the massive Brainchild logo on the side. Very smart looking building made out of two. Two parts. One's like a big warehousey looking thing and the other one looks like a big office block. And it's much bigger in size than I remember last year. Cool. And there's a bay tree or an olive tree. Is it one of each? Either side, Some sliding doors as we go in. And there he is. Welcome, welcome.

[B]

Hello.

[A]

I'm good. How are you?

[B]

Well, I could pretty much have a little bit more sleep. Yeah.

[A]

With.

[B]

I would say a little bit less drama. Okay. Still, we're going to the office first so that you can get your backpack, mate.

[A]

Look at this.

[B]

Well, it's not finished. The. The cafeteria is missing the bar and the couches and everything, but we sit on the floor. Oh, well, we don't have to do that actually, but we can sit here and. Or you can basically. Yeah, it's, you know, like. Yeah, it's the view also, which I really. Yeah, I really, really enjoy. That's one of the reasons why we're here in the end. So all the mountains in the valley.

[A]

We're looking at a huge mountain range

[B]

and still we have snow. You can see that on the top of the mountain.

[A]

Yeah. So what altitude are we at here?

[B]

650.

[A]

Yeah, I was feeling a bit unfit now. I know. That's why. Yeah. And when did you get back from Mykonos?

[B]

Yesterday.

[A]

Yeah. Yeah. Okay. It was a good trip for you.

[B]

Sort of successful.

[A]

Very successful.

[B]

You'd have to.

[A]

You'd have to say, hey, guys, you want anything here?

[B]

Dutch thingies. Just tell me something or something else.

[A]

That's good. Honestly, we're good. Yeah, we're good. Yeah. We've been like drinking and sitting in the car.

[B]

Yeah.

[A]

So we're happy. The idea is to bring the audience, give the audience a audio experience of coming to Brainchild, which is exactly the sort of thing I would want if I wasn't here. So I'm excited. But this building is epic.

[B]

It's not too bad. Yeah, it's quite nice.

[A]

Yeah.

[B]

No, I mean, I think last time when you have been here, I think we stand just on the road I think. Yeah, yeah, yeah, I remember. Yeah, I remember us looking at it and then technically, yeah, now we're in. So this is pretty much where it is. We also bought the land here on that side. And then we have an extension of the land behind the building. So this is also giving us some room for growth.

[A]

And the lab is here or the lab. The lab is in the original.

[B]

The lab is still there, but it's actually 50% bigger than what you have been seeing. Oh, shit. So it's 1,700 square meter lab. But I also have to say that the lab itself, there's just like really restricted areas. Like the new building in the lab is not like, I cannot show you.

[A]

Yeah.

[B]

Because this is where we do the material development. And as brainchild wants.

[A]

I love, I love that you think I would be able to understand what I'm saying. Well, that makes me feel good.

[B]

Well, well, there's some stuff which is so flashy, let's put it this way. But I mean, this is just to give you a quick update. I think we talked about it. Like for us it's more right now in that phase from the lab to the manufacturing. And I'm luckily now going back to the lab what I like to do and being creative over there. And then in the lab we try to come up with the material solutions. So really from material to product. Because if you look into the history of kitesurfing, there was literally never really a company dedicating making material specifically for the kitesurfing industry. For example, Alula has nothing to do. Alula is a material which shouldn't be in a kite technically. And then it. It took years basically to make it work. And many of these materials are not purposely designed to be in a kite. And we try to change that because

[A]

what Dacron was Ripstock for tents.

[B]

Well, Dacron is actually just a wide sail for the sailing industry. You know, like that. That is basically what it is. And for example, the canopy material is a spinnaker material for sailboats. So everything. The origin of our sport is not wind surfing. The origin is sailboat sailing sails classical. And of course, like the. The technical properties behind that application is not what we actually would need in our industry. So I'll try to change that. Also, it's price to value, of course. You know, like, if I can just purposely design something, I might. Might have the chance also to reduce the costs a little bit, especially when it comes to lamination.

[A]

Epic.

[B]

How simple is that?

[A]

Does sound really simple. I liked as well that it was a Skoda that picked us up. Yeah.

[B]

And exactly.

[A]

Yeah.

[B]

This company policy, it has to be a Skoda.

[A]

The first time I ever interviewed Ralph, I was like, you seem to. I just don't understand why you would drive a Skoda. And he was like, because it's the product market fit.

[B]

Yeah, exactly. Yeah, that's true.

[A]

That's good. That's good. Do you think it's worth us going to the lab today?

[B]

The thing is the lab itself. We can go to the lab, there's no problem. I just can't introduce you to the really fancy side of it.

[A]

But we're really here to look at this building.

[B]

Exactly. So for me. But I mean, you can just. For the contrast, to show the contrast between the two different concepts, it surely makes sense to show it at least this one room. But then we. Anyway, we are passing by. Angel. Yeah, that's not a problem. I mean, here we still have a shift running, so still people are working in a lab. Surely not. Or maybe on the cutting side, I don't know. Yeah, but I mean, I think this is. I mean, again, Ben, just to summarize it, in the beginning, it's innovation, which should leads to duplication.

[A]

Yeah, yeah.

[B]

And that's the reason why it's like really also apart from each other. 15 kilometers, literally. Oha.

[A]

Whoa.

[B]

Oh, my God. Okay, thank you very much. Cold water and real glass. Satlana is running. Sadana is the. Is running everything over here. So she is the manager. Very good. And the trouble solver. Yes, and there's a lot of trouble, so. A lot, A lot of trouble to be solved in cooperation with Diane. Yeah, Diane can fix everything until the point. Exactly. Great.

[A]

Nice. Thank you.

[B]

Yeah, exactly. See you down there.

[A]

We're excited.

[B]

Super. Perfect.

[A]

I remember last time there was a

[B]

young Macedonian girl, Natalia. She is working in the lab.

[A]

Cool.

[B]

And Svetlana, she has been working over there at Kromberg Kombuch. Schubert is the biggest, biggest single employee in North Macedonia with in total 14,000 employees over there, 5,000 employees. They make cable trees for cars, wiring harness, basically. And she has been in the management team over there. So my management team actually comes from there, from automotive cool, which is really new. Very different in the industry, like normally.

[A]

So she knows how to run a production line. She.

[B]

No, she technically set up the entire thing over here. Like everything. Everything. You see the decisions. Of course, it was based on my ideas, but I would definitely not claim that I have done it. You know, like, it's my idea, but the fulfillment goes to my team 100% cool. You know, because I'm already splitting myself into 10 equal pieces per day, sometimes to 15 or 20. I cannot do more than this.

[A]

You do an enormous job. Eh?

[B]

It's insane. Yeah. Hopefully I can.

[A]

Are you enjoying it still?

[B]

I'm sick. Is that a question?

[A]

Yeah.

[B]

Well, I'm still doing it.

[A]

Yeah. Yeah.

[B]

But it's, It's. It's tough.

[A]

Yeah.

[B]

In project like this, we have 235 employees now, you know, and like just in. In that short time period on having. Working for different customers, which is not easy in first place. And basically with. With everything involved, running such a thing or creating such a thing itself is. Is a huge achievement. And the building was made in eight months.

[A]

Wow.

[B]

In eight months. You know, and in 10 months, including all the paperwork, this is just, I think, like, I don't know even how they did it. Technically. It's absolutely insane.

[A]

Wow, great. And the factory itself, this building.

[B]

Yeah.

[A]

This was your dream.

[B]

Yeah. I would say this is like. When you look at it, how we done it, and later when you see how we did the structure, it's so nice to see that whenever you have the chance to really plan things from A to Z, that. That automatically you have a better product. Yeah. In the lab. Hey, in the lab. In the end, we couldn't walk anymore, you know, like this. It was impossible. Like, we had no idea where to inflate the products. It just ran out of space entirely. And it was horrible. Like it was. For me, it was a disaster because I could not do the things I would like to do because this was not ready. The other one was just like exploding because of the demand from our clients. And right now we have just a perfect ideal scenario. We left quite a lot of space in between everything. So currently we're doing 60 kites per day. But we can easily do 120 when we just use the space easily, that gets absolutely no problem. Or even going bigger or bigger in this regard. But everything is purposely done, really. There is no corner where you said, oh, that's a stupid corner. We're losing some space. So everything is really done with a logic in first place. So cool.

[A]

Epic. All right. I really want to look around.

[B]

Yeah, have a look.

[A]

We all like to leave stuff in here.

[B]

Absolutely. This is very safe here. And you could leave it on the street. No one would seal it.

[A]

Before Arne takes any pictures, is there anything you don't want photographed?

[B]

Yeah. So what is. What is? We have. So right now we have not moved our entire digital printing and colandering department from the lab in here because we have been like had massive delays of components. So there is like, we just set it up a certain infrastructure for the Prime Minister. Because the prime minister is coming. Oh yeah.

[A]

Cool.

[B]

Yeah. I mean the prime minister half of was it ethic. Half of the North Macedonian government was here. Hey. It was snipers on the roof. Huh. And road blockage of a lot.

[A]

How was your good. Good day for practicing the handshake?

[B]

Oh, I was, I was.

[A]

Yeah.

[B]

I had. Of course I had a speech, you know, and then. Oh my God, you know.

[A]

So cool.

[B]

No, it was cool. It was. Was great for everybody. Yeah. Maybe. Maybe this. But I will, I will pinpoint it. I mean it's not a problem. But it's not. Yeah, it shows not the right things. I mean, cool. It's every. Everyone from production would say like this is not what they are doing there. Because it's clear that we are not doing it here because we're doing it in the laboratory.

[A]

Okay. We really want photos though of you. And then just like the factory, like building in general, something on the floor. We don't need too much.

[B]

Yeah. And I mean this stuff we don't even have to do. We basically do this.

[A]

Okay, here we go. We're walking in w. So very clean. Ooh,

[B]

it's huge.

[A]

Yeah, it's huge.

[B]

Well, it's three and a half thousand square meters and you just see half of it right now.

[A]

Wow.

[B]

Yeah. So I mean to also to explain a little bit the concept. For example, I mean, we are here now in second shift. Yeah. You guys are late.

[A]

Yeah.

[B]

So only certain parts are actually doing two shifts and only cutting is doing sometimes three shifts. So that over here, this little department, this is all accessory. This is what it needs. And then in the end, of course, if you have a lean production, every single machine is occupied by one operator. And that makes actually everything very optimized.

[A]

Yeah. So everyone's doing one specific.

[B]

Exactly. And it's really in sequence. Yeah, it's really, really, really much in sequence. And whatever kind of accessory. I mean you of course our, our bags. But we have a lot of stuff for unica. Yeah, A lot of different kind of varieties is basically in here. And this is wonderful to see because if we, if we know, okay, we have to extend it. We just extend it, you know, like there is always some, some more space in this area. For example. Over there we have everything which doesn't fit into the product in the. Into the production line itself. So the small items, if you have to create pockets for the leading edge, the struts, reinforcements. It's basically been done there also to be optimized. Again, you can see this is the. Basically, this is the walkway which is defined. And if we extend our production, if we increase capacity, then we're just adding another line. But still the infrastructure is there. So it's always. That is the key learning. Because we added more space, knowing. Yeah. That if we are successful, that we actually have to grow into it. That we have to grow into it and not be in the same position as we have been in a lab where we just ran out of space here. Not really. That will take basically years to run out of space until the point there you squeeze the things in.

[A]

Cool.

[B]

Should we do like a tour from raw material to final product?

[A]

I would love that.

[B]

Super.

[A]

I love that. Yeah. Okay. So we're walking across the factory floor now. There are bright lights everywhere, clean floors, maybe 50 people working at the moment in this room. Now we're starting in the warehousing bit with raw materials.

[B]

Yes, exactly. This is where the raw materials are coming in. This is our warehouse also here. Everything a little more structured. Like just these rows of materials is a quarter million euros of raw material just is behind here. I'm not going too much into the specifics because this is of course, also. Shouldn't be shown too much in detail.

[A]

Yeah. Okay.

[B]

Now this is always. But, yeah. So it starts with opening that door. This is where the raw material comes in. And I will just like to. Just like to show you how the building actually and how it's a nice door. That's a nice door.

[A]

Quite quiet.

[B]

Yeah, yeah. Still quiet, but definitely going to be more noisy soon.

[A]

How many unique materials or how many unique parts kind of go into it? Whoa.

[B]

I have absolutely no idea. Unique materials, like technically, pretty much everything is customized for us. It doesn't matter. Like, even these materials, you know, like they are. You cannot buy them off the shelf. You have to buy tons of material and then you do the specification. So we run, I would say, for 90% of the materials, different specifications as anybody else in the world. Because our application is different or slightly different. That is basically. So that is just that. You have seen it. This is basically the extension area. So this is where the next hole is going to be taking place. Yeah. And then we will have a bridge or tunnel or something to make sure that, like, the halls are connected.

[A]

So we've gone outside and we're looking at where a lorry would come and drop off stuff. It's a section of land just next door that a second hall is going to go on. And it's the same size.

[B]

It's. It's like. No, it's, it's smaller. But we just buying the exact same land on the other side.

[A]

Ah, got you.

[B]

At the moment.

[A]

Okay, cool.

[B]

But also mainly because I don't want that someone builds there and then I don't have a few. It doesn't make sense, right?

[A]

No, it'd be bad, very bad for company culture.

[B]

Just imagine there's still the view from me.

[A]

Yeah.

[B]

I came here because of the view. It's so unfortunate that you can't see. This valley is so beautiful. I mean, we have. On the right side here we have one of the highest mountains in Greece. Two and a half thousand meters. Yeah. Then Pelleston Mountain here in Bitola is 2,200. And this valley is just continues, I think 50 kilometers or 40 kilometers to the north. It's just on a nice day. It's epic. It's really epic. And this is something which I really like that we are still in nature somehow.

[A]

Yeah.

[B]

So let's go. Raw material is coming in and what then happens is that we have these doors over here and as you can see. Let me switch on that is here. I mean, it doesn't make any sense to make pictures because normally our digital printing machines, we have six of them, are staying here and they require no space. This machine is actually technically here for the Prime Minister. So we are not even using this one. The machines look a little bit different. Maybe you can remember a bit higher. But just to give you a number, we had. I mean, we have six of the same machines and we had a maintenance job done for one of them. And it shows you how much square meter of material it has been printed in the last two years.

[A]

Yeah.

[B]

And one machine did 181,000 square meters alone.

[A]

And you have six of them.

[B]

They are not. We bought them step by step, but we have some with the same number.

[A]

Yeah.

[B]

So 180,000 per machine.

[A]

And now we've just turned around and I can see what is this printed on?

[B]

It should be canvas from here, but I'm canvas of.

[A]

But I think that's Baptiste with.

[B]

I mean, it's a bit hard to say as he is wearing a camera in his mouth.

[A]

Aaron or Baptiste?

[B]

No, I think about it. I'm not. So is it Baptiste? Yeah, it's Batiston short lines. I think it must be Batiston short

[A]

lines on Harlem Peak above this, above the horizon. In Mykonos, where it would just be. Yeah, very good.

[B]

Yes. Well, we also did that here to showcase a little bit what we're doing. This is the reason why there are these boards.

[A]

Am I getting the same treatment as the prime minister?

[B]

Kind of, yeah.

[A]

Good.

[B]

Kind of.

[A]

I deserve it.

[B]

And then I'll can show you this. So this is the. The calendaring. Also here is a little bit problematic to really show because these machines are.

[A]

Okay.

[B]

I wouldn't like. I. I know it's boring, you know, but it is really. I would not like. But you see huge exhaust systems.

[A]

Yeah.

[B]

Four machines of the same type.

[A]

So this is another printing room.

[B]

No, it's there. That is the colandering. So this is where the colorization of the fabric takes place. So this is basically white material in and then colored material out. This is how it looks. So we're looking at the coloring process. Just like the sheets of it.

[A]

Sheet of uncut material. And what part of the kite would this end up becoming?

[B]

Well, this is accessory. This is a shoulder strap. This is the front panel of old version.

[A]

Yes.

[B]

These are the backpacks. But like the logics are kind of the same. For example, here we have struct of a new thrive. This is how it looks like. This is basically epic.

[A]

Yeah, this is.

[B]

That's the strut material. As you can see, it's a film.

[A]

And what's this material called?

[B]

Well, it's a laminate as well. It's written on it.

[A]

And it's got.

[B]

I'm just realizing it's got the.

[A]

It's the sound. That's the brainchild sound.

[B]

It's. It's the brainchild sound. Exactly. We should not write on it.

[A]

Don't worry about it. Don't worry about it.

[B]

Yeah. But for example, here we do the material test. The material runs through the machine. This is just a light box. Oh, yeah. So this illuminates. And then we are finding the material defects. And if it's really problematic, then we're taping it. And then we know exactly that we can't use it for cutting. But these machines four times. And then the printing comes in here. It's the material itself. Get colored, goes on the table. And from here it goes to the second step. And maybe I can show you, even as it's not always saying what it is,

[A]

it looks so cool. It's unbelievably saying. It's almost translucent.

[B]

Yeah. But this is, for example, that is this under the table. Because the material has stains. So this is a reject. But we have been using, by the way, we are also using this. And we are not throwing it away. We are making bags out of this, you know, like for beach bags or something.

[A]

Yeah, yeah.

[B]

So this is. That's way too expensive. But yeah, you can see we try to keep it really straightforward. Yeah. Really optimized. Very important is the climatization.

[A]

Yeah.

[B]

So the temperature has to be in the range of 2 degrees. Normally 21 to. Yeah, technically you could go to 24, but 21 to 23, that's perfect. Okay, then, then once here, straight into the cutting. This is where most of the cutting takes place. We have a laser on that side.

[A]

Yeah.

[B]

And two oscillating knives over there. Unfortunately, we are second shift, so I just can't show you.

[A]

That's right. Yeah, imagine.

[B]

But we can also always provide you some footage if you like. No, like. Like video footage.

[A]

So.

[B]

Yeah.

[A]

The material is coming in colored in this room. Then it comes into here. If it passed the quality control.

[B]

Yes.

[A]

Then it's sucked onto the table.

[B]

Absolutely. That's very important. Yes. And then lasered. Or it's the oscillating knife. Where with the oscillating knife you can actually do multiple layers. You could go 30 layers easily if you want. Yeah. So that of course reduces the costs. This is normal. This is standard procedure. Everyone is doing that. We have quite advanced machine. I do not like to talk about what they can do. But it's also customized. Like it's a customized for us. Basically the application is customized. And here it's the space for the second laser. So we will have two lasers and two oscillators.

[A]

These lasers and oscillators are huge, huge tables. Much, much bigger than a full size snooker table. Maybe three full size snooker tables. And the laser spans the whole thing.

[B]

Epic. So let's go further. It's also the concept this time is that every worker has like an access card so that the people are not like running around but being much more focused on what they actually have to do. And I think that is like the perfect example. Now this is not only part of the quality control, because this is the cup panel in this regard. From a thrive too. Like from the 2026 thrive from the second generation. And here the light table does two things. One is marking the canopy line because somehow you have to draw a line on the company which is indicated by laser dots. Yeah. So. So in the end you have like laser marks. These ones.

[A]

Wow.

[B]

And basically the lady is actually aligning according to these laser marks. Like these ones for Example, they're showing where the Velcro is sitting. Yeah, yeah. So this is. It's clear how it's been done. And then you can see all the cutouts are already there for the inflation well, for the zipper. Everything is there. And this is even already in the right sequence. Yeah. So that is very important that we really go step by step, that we do, like, massive detailing. Because here we could still duplicate stuff and without a damage. But imagine there's, like, one little yarn missing, and you put the stuff together, and then in the end, you have a kite and you have to reject it because of a yarn.

[A]

So what happens now with these laser marks?

[B]

So, like, some of the marks are. Let me quickly see.

[A]

First to line up before it gets glued and stitched.

[B]

Yeah, exactly. Like, this is, for example, this mark. And this mark over there, this is the canopy line. So she's drawing a line over here. Yeah. Just to make sure that later on when the canopy is attached, that the ladies know exactly how to attach it. That's very important.

[A]

You know, I say, ladies, it is almost entirely a female workforce.

[B]

It is, yeah. Finally, cutting is entirely male. Like digital printing, calendaring and cutting is male. And the work is female. Yeah.

[A]

Is that by design? Have you made that decision?

[B]

No, absolutely not. No. Why. Why wouldn't we? No, absolutely. No, no, no. The mechanics are males as well. It's just. Well, it seems to be kind of a natural order.

[A]

And I guess that was how it is in the rest of North Macedonia, maybe in the massive textile industry, I would say.

[B]

Yeah, you always have. I mean, it seems to be the natural.

[A]

You wear the world. Yeah.

[B]

Cool.

[A]

And 250 people working at this 235. So that's too many people for you to know each of them individually? Absolutely, yeah.

[B]

I have no idea. Yeah, I know my management team and then the supervisors.

[A]

I think it was 50. I think you had 50 people last time. Last time we came.

[B]

Okay.

[A]

And you knew them, but. Yeah. So it's times for life.

[B]

No, I can not.

[A]

Yeah, no wonder.

[B]

I cannot remember. It's too much like. I mean, as we are. Like, we have very familiar faces, the ones from the beginning, which are now in the supervisor position because they have the knowledge. But generally saying, like, we have been growing so much over here that I haven't followed it up.

[A]

Yeah, fair enough. Okay. Yeah.

[B]

And then basically, what happens is production divides into two different lanes. We have the canopy lane and we have the leading edge strut lane. So on the right side, this is where the leading edge and the Struts are made and on the left side, the canopy. And technically, as you can see, it's looking a little bit different. The height of the table is different. Here the tables are lower because no one is standing on the table. But the moment you're standing and sewing. Because what they do is they feed each other, unfortunately, second shift at the moment, normally, so that they do the gluing feed over to the sewing lady, she's doing the seam and directly goes to the next working step. Yeah, so it's really like a. It's like a zigzagging. It's like tuck, tuck, tuck, tuck, tuck, tuck, tuck. Like from every position. And at the end of this line, the entire canopy is done.

[A]

Wow.

[B]

Yeah, from here to there. That's it.

[A]

And we're looking at what, 30 meters?

[B]

I guess. So now even a little bit less, maybe 25. And the same happens with the leading edge. So this is what it requires to basically make the leading edge work. And then at the end, we. Combining the things. Yeah, the leading edge.

[A]

Let's go there. I would have to look at that. Sure. And which is a more technically difficult bit to assemble, is it a leading edge? Yeah, leading edge.

[B]

Leading edge is way more technical, requires more. Way more precision.

[A]

Why is that?

[B]

Well, because like a millimeter in difference on the leading edge is creating a distortion in the leading edge itself. And that would basically result into a twist. And it's extremely. Hello. It's extremely important to understand, like, which part can be twisted or could have a little error and which. Not here, for example, what we do right now, what a lady is doing.

[A]

We're just looking over the shoulder of a lady working on leading edge.

[B]

And she is making. Now, as I can see, this is going to set a valve disc. So this is the valve for an inflate for a one pump system.

[A]

Oh, wow. So fast and efficient, eh?

[B]

So some free trimming, but the trimming also will follow later.

[A]

She made that look easy. Even with her boss's boss's boss looking over at a shoulder.

[B]

Yeah. But they're used to it. From time to time. I'm coming and looking over the shoulder. So they're used to. Yeah, and. And yeah, as well. Over there. You see, like it is totally in sequence. One lady is doing one. Passing it on, passing it on, passing it on. And then you can see also that if you have the leading edge, you have to attach the strut to it. Once you attach the strut, because this is like another dimension to it. And once we have done this, another Dimension, the second dimension. Then basically over here is the combining co. Yeah. Or partially. Also over there. Depends a little bit now. So she's setting the glue for the canopy. Yeah. So this is like. That's very important because everything is always glued and stitched.

[A]

Yeah.

[B]

We can go to the other side.

[A]

Central to the DNA or brainchild.

[B]

No, but it's also part like how you do it, because the glue, like very, very often the stitching is just there to secure the glue.

[A]

Yeah, that's what people always say to me. They're like the brainchild kite. I can see that it's stitched, but your answer is that.

[B]

Yeah, well, I mean, it's, for example, also with the pro world. I mean, technically we have two things. We have the pro world itself. Then we glue. We have a backing with glue on the backside. But ultimately we have to add the webbing, which ensures that the. The pro weld seam is not getting hurt from stone, sand, whatever. And this we can only stitch.

[A]

Yeah.

[B]

So technically it is also stitched, but not from. From the way the material works together. Because this stitching only holds the webbing, but it has no function than holding the webbing to it. The pro weld is basically the idea behind it. But you can see this is like, this is the line we have seen in the beginning. This is basically now what it is. And then we are getting over there, manual work also making sure that everything fine. Because every little step also can be used as a quality step. Next one.

[A]

Man, this is cool here.

[B]

As I said, like, this is basically combining. This is a little bit. That is a repair. That's the reason why we have these things over here. So maybe we can. Can move that out and basically go to. Because I don't care, but others will. Yeah.

[A]

So that's. That's sensitive.

[B]

For example, these machines are the most expensive you can buy. You know, like these juki long arm machines. Wow. €12,000amachine.

[A]

Oh, my goodness.

[B]

It's a proper car.

[A]

So when did that bladder get inserted? Where does that happen?

[B]

Over there? Let's move on. We are not done yet. Yeah, you can. There's no worry. Yeah, no problem. Exactly.

[A]

This. Oh, this is a bridal ladies. Bridal station.

[B]

Bridal station, yeah. Automatization. Wherever it's needed. You know, there's also an automated machine for making the line stitch. So basically the stitching of the line is happening over there.

[A]

Yeah.

[B]

So we're optimizing this for sure. Later we can see that again. And the ladies are working. Always keep in mind, first Shift. Every single work, every single operation is set. You know, like, there's no people not working on. This is just. Now this is just second shift. It works in a different way. That is closing, meeting edge closing. That is kind of the most difficult.

[A]

Ah, so these are your most experienced sewing people.

[B]

Oh, yeah. By far. This is like basically, yeah. What we are doing. So here it's for example, if we. If we find any mistake, this is reword. Sounds crazy, but this is totally normal and part of the process. I would rather not to have it because then people are complaining, but whatever. But this is, for example, if we feel that there's a mismatch.

[A]

Yeah.

[B]

Then we are actually going. We're going like, we're going basically with the last step. But here maybe it's something interesting and nice to see, like how the puzzle. And maybe we can just follow the puzzle a little bit, how the puzzle is actually happening. So on one side we have the joining of the panels. And then what happens is like that we are adding the reinforcement parts of it. And yeah. The colorization, for example, of the material is because we have. We're adding and we have two different materials. And to match them ultimately under sunlight, we do this. Oh, wow.

[A]

Yeah. These are the wingtips.

[B]

We're looking at master model wing tips.

[A]

Wow. Yeah. It's an hour and the end room.

[B]

Final assembly.

[A]

It's probably got. How many kites are we looking at here?

[B]

100.

[A]

Wow.

[B]

100 plus. 100 crushed. 110.

[A]

Maybe 110 fresh brainchilds.

[B]

Oh, more like. I don't know. May Hard to tell.

[A]

I mean, it is so Nice to see 100 plus. Yeah.

[B]

100 plus kite.

[A]

For sure. We're doing final checks and we can go in.

[B]

You know, also you can just go somewhere in like into the forest here. Into the forest.

[A]

Okay. We're walking amongst them now.

[B]

I mean, look at the stack.

[A]

You know, like, this is thick of

[B]

the things we're doing.

[A]

Even smells nice.

[B]

They always. Brainchild products always smell good.

[A]

And they've all got that such distinctive brainchild sound. It's like a crinkle, isn't it? That's.

[B]

That's true. Yeah. And. And here you can also see with the next generation of the thrive, like how much we have been working also on the colors.

[A]

Yeah. So. So intricate.

[B]

Yeah, it is really. It's really, really, really next level of also of. Of like detailing in the end. So what is very important in here, the kites are getting inflated twice, each time for 24 hours.

[A]

Ah.

[B]

If there is a mistake which can happen. Then it goes again for 24 hours. So no kite is leaving without these two checks. Yeah, and that's really important because not always the comments. That kite never has been inflated in production. No, I can tell you that is not the case. We can also go over there.

[A]

We're just seeing a trigger brainchild being inflated here. Amazing. Purple and red. As Holland thrives as read ins everywhere. Ah, the inflation station.

[B]

That is a classical second time inflation. Hello, Pavlina. She's the floor manager, basically. Yeah, yeah. So Pavlina takes care basically about the floor, whereas Solana takes care about everything. Okay, that. That's the difference.

[A]

So you've just inflated this one.

[B]

Yes.

[A]

To what PSI did you do? PSI. What pressure?

[B]

8.5. Usually between 8 and 9.

[A]

Very good.

[B]

But never below 8. Let's put it this way.

[A]

Yeah.

[B]

And what we also doing, we're checking for symmetry. That means like if the, if the sides of the kites are balanced, there's always, always a certain difference. It's mathematically possible to have zero, but it is in the range of a couple of centimeters. So we are checking like how the material actually handles. And there's also the reason why we have to say like we need minimum 8 psi to actually get the right.

[A]

Yeah.

[B]

Form of it.

[A]

It's so cool to see a fully assembled one. The trigger.

[B]

Yeah, that's the V3, the new model which comes out this week.

[A]

Oh, cool. And I'm looking at the bridle.

[B]

Yeah.

[A]

It does have pulleys.

[B]

It does have pulleys. It has the, the. The. Exactly. And the F1 pulley. So. Which is quite a cool system actually because as you can see the, the dilemma line runs around the pulley. So even if the plastic would break, you would be still secured because you're in the loop. Yeah, it's very clever.

[A]

I haven't seen that before.

[B]

Yeah, exactly. So this is really, really nice.

[A]

Is that an F1 invention or.

[B]

It's an F1. No, it's an F1 invention.

[A]

That is cool.

[B]

That's an F1 invention.

[A]

Yeah.

[B]

So this is really cool. I like that idea. It's a bit more work because you have to splice it in there and then basically now you can see you have to tack it there. You have to tack it there. You have to take it there. So it's quite a lot of work, but it's a wonderful thing. And you should try the kite. You will love it, I can tell you. Yeah, that's a like mega second lift. That One.

[A]

And you're not known for your. I know you like fixed line depending on the kite. Oh, yeah.

[B]

Really? Like, this is like. I mean, the pulley. What the pulley actually does is it creates a little bit more longer d power stroke. So when you're sheeting out. Okay. On a pulley kite, you have. You are attached a little bit longer to the back lines. Yeah. That is very important. So. So you. You gain. With the pulley, you technically gain 2cm of more being attached.

[A]

Okay.

[B]

To the back lines while he powered.

[A]

Okay.

[B]

That's kind of the thing. And because it's a fixed bridle, when you're turning to the right, the left can open up a little bit more. But it's very important to understand that the pulley here never moves more than 2 centimeters.

[A]

Yeah. Because it has the. Yeah.

[B]

It's basically just doing this. But that is completely enough.

[A]

Wow.

[B]

The movement of two.

[A]

It's not going the whole way. No, no, no, no, no, no, no. That's never.

[B]

No, no, no. Two centimeters of range.

[A]

Amazing.

[B]

But two centimeters is already enough.

[A]

Yeah. Yeah. Wow. Yeah. Wow.

[B]

Here we have the packing. And this is actually where the journey ends or starts, depending on how you want to see it. This is. This is the. The packing. Then that is the door where the range head product leaves production.

[A]

Cool. A lorry comes.

[B]

A lorry comes.

[A]

Where's the lorry go back into Europe?

[B]

Well, the lorry drives normally directly to the Netherlands for Ren and Harlem. So we have our transportation.

[A]

Yeah.

[B]

And then the lorry normally continues to France to F1.

[A]

Okay.

[B]

So it's. It's basically a circle. So it's kind of not always the same lorry, but it's. It's. It's kind of a loop.

[A]

Cool. And how often is that loop occurring?

[B]

Once per week.

[A]

Oh, wow. Okay. It's often effort.

[B]

We have shipping once per week.

[A]

Effort. Well, the finish is amazing. The amount of detail in the printing and then the stitching and the engineering. What's the secret to a kite being kind of crisp and almost like folded when it arrives?

[B]

Crispy ends.

[A]

Almost like without creases.

[B]

Without creases. It actually does have creases in the end. It really, really depends on the material. For example, this one is a medium soft finish. Material like that one feels different to, let's say the one of on the thrive. So it's a. Like it. This one makes also a different sound. Like this one, for example. Yeah. Like if you touch this one, it's not the same as this one. Yeah. Now here this is like here. That is basically. This is softer.

[A]

Yeah.

[B]

And that is also again, another material which is. Yeah. This is the thinnest available material on the market. This is only. That is the Thrive Lite X, which is in the class of the whisper. That is the lightest material ever used. 32 grams.

[A]

Can I touch it?

[B]

Of course. Yeah. Kenny, it's 32 grams.

[A]

That is like.

[B]

That is nothing.

[A]

Your grandma's tissue paper.

[B]

It is. It is. Yeah. But it holds.

[A]

Wow.

[B]

And that is the very simple and very easy, straightforward journey of a kited brainchild.

[A]

There we go. Well, thank you for showing us. I loved it. I feel like I've learned lots too, and epic to see the progression from the first location to this. This is different. It's a whole different beast.

[B]

It is completely different.

[A]

Just to be stood in a room with 110 inflated kites is actually quite.

[B]

And they all look so nice.

[A]

They do look nice. I was about to ask you which one's your favorite, but obviously you're not going to tell me.

[B]

No, I'm. Well, it always depends. But I mean, for us it's very important to have like this progression in printing, in printing quality, for example. And of course here, like with these pop up lollipop, as I call it, lollipop colors. Chuba Chum. How is it called? Like this little Chuba Chum. Something. But also like in. In the air. Like the trigger looks amazing. You know, like this. These colors are absolutely insane.

[A]

So they're shining lights through here.

[B]

Yeah, because they're checking if the bladder is twisted. So that is the only way because you can't see through. So you have to have a light source and with the light source you're checking if the. Yeah. If there's a twist. It's actually quite. Quite simple. Yeah. I think we made a little bit of progress and huge. And I think that's. I don't know if you want to tell, but I mean, for me it's very important to also to showcase what we have been achieving from the lab. From having three employees figuring out the digital printing for a year, literally, and then progressing in two years to 235 people in the most modern production facility. And of course now having a completely different focus on the product itself. You know, these people here, hamming from automotive, they are focused on quality.

[A]

Yeah.

[B]

You know, so I can focus on. On the innovation again. So I can go back to the drawing board and hopefully being able to come up with some cool new ideas, by the way, which I will, I believe that.

[A]

Shall we go and have a cup of tea?

[B]

Absolutely, let's have a cup of tea.

[A]

And these people would all live locally in Vessela, maybe. Yeah.

[B]

Also in pre lab. So we have a bus or buses and we're bringing the people basically to their hometown.

[A]

How have you been able to buy these keeper from automotive? Do you offer them better pay or better working conditions or how does that walk into the automotive factory and say you. How does it work?

[B]

No, but I mean a lot of these ladies do have a suing background.

[A]

Yeah.

[B]

There are not really many coming from the automotive. I would say it's. It's more that the. For example, if a company closes down in for suing clause or apparel, then of course, you know, the people know us. I think Brainchild is extremely well known in this little country, the Republic of North Macedonia. I think also the people are quite proud about what they're doing in here, you know, like competing against the rest of the world. Yeah, literally is. Yeah, it's. No, I think it's the package. Always you have to create the right package for the people. And it seems that we can do that.

[A]

Cool.

[B]

It's a bit of a shame that we just have half of the stuff right now here because it's very nice and I like the. The sound, you know, the sound of. It's good when all the machines are running. You know, like you're coming in here and. And it's. It's for me. It's all. Even for me. After 26 years in kite surfing and over 30 years in the industry itself, knowing that the kite starts over there. And in the end of that line, it's done, you know, like, it's kind of. And it's an. It's an, I think, quite a. Quite a nice journey.

[A]

All right.

[B]

Yeah, exactly.

[A]

And the balloons.

[B]

These are for me and the balloons. It says it's only for you. Only for you. And maybe we can see. Yeah. And of course, you know, I think this is kind what it speaks for itself. Like what we really achieved with Brainchild is like really this absolutely matching. You know, that is the flow, that is the peak, that is the new thrive. And to really see when you like putting these kites next to each other, all the patterns, all the logics are just reflected in here. Or the classical stripes from Mr. Hadlow. Pro kite must have stripes, you know, like from the. If you're the Englishman.

[A]

This is epic.

[B]

Yeah. So it's. I think there's just so much cool stuff you can do and, and really, you know, like, feeling it a little bit more. I think that's quite, quite a cool thing.

[A]

And these bags are produced in here.

[B]

Here.

[A]

So the people that are capable of producing. Yeah, world championship winning kites.

[B]

Absolutely.

[A]

Are also making bags.

[B]

Of course, also making bags.

[A]

And unfortunately, very overqualified bag makers.

[B]

No, they, they. Well, I mean, it's not that simple making these bags. Let's see if I find some other samples. But maybe I actually don't know where the stuff is. But look, for example, you know, like, when you're just looking into the little box. This is a pouch for Unica. And how cool this looks, you know, like this, to have these, these patterns, knowing that it went all through our process. I don't know, I mean, I love it, you know, like, I like, I like this, the feel and look of the colors and like how it shines, you know, like, and how, how much I think of a quality it is ultimately. And by the way, all these plastic parts are coming from Germany, not from China. This is recycled PET still. The buckles are coming from us, from the wood which we are purchasing locally. So nothing has changed. We are still getting the super expensive recycled PET stuff from the Germans.

[A]

Is that your office?

[B]

No, that is Pabina's office. Technically, I do have an office, but I'm literally never here. I'm just here for meetings because my office is in the lab.