Manufacturing of magnet wire (enamelled wire) and continuously transposed cable (CTC) for automotive, energy, industrial and transportation applications.
Essex Solutions Inc. (Superior Essex / LS Group)
Bad Arolsen (DE) · Bramsche (DE) · Fort Wayne, Indiana (US) · Quattordio (IT) · Suzhou (CN) · Kameyama (JP)New on Amplifa
About Essex Solutions
Essex Solutions (brand group of Superior Essex) is a globally active manufacturer of magnet wire (winding wire/enamelled wire) and Continuously Transposed Cable (CTC) headquartered in Fort Wayne, Indiana, and part of the Korean LS Group. The company produces film-insulated and overwrapped copper conductors with temperature classes from 120 °C to above 260 °C, including the product lines EnduroTemp® 260+, HVWW®, UltraShield® Plus and Magnebond®/Magnesol®/Magnetemp®. Manufacturing is vertically integrated – from high-conductivity copper rod and copper wire to the finished, laminated or overwrapped conductor – and comprises 28 sites worldwide with an annual capacity of around 420,000 MT. In Europe, Essex Solutions produces at the German plants in Bad Arolsen and Bramsche as well as in Quattordio (Italy). Customer industries include Automotive (electrification, traction motors), Energy (transformers, generators, renewables), Transportation (aerospace, marine, e-mobility), Industrial (electric motors, welding, HVAC) as well as commercial/residential applications. Customer-specific developments are carried out at the MagForceX® Innovation Centers, among others in Bad Arolsen and Fort Wayne.
- Site
- Fort Wayne, Indiana
- Processes
- Magnet wire production (enamelled wires, e.g. Magnetemp, Magnesol, Magnebond), Continuously Transposed Cable (CTC) production – film-insulated rectangular conductors, overwrapped, EnduroTemp® 260+ magnet wire production (260 °C, increased current density, fast heat dissipation), HVWW® high-voltage magnet wire production (240°C/220°C+, PDIV- and corona-resistant), UltraShield® Plus magnet wire production (200 °C, inverter-compatible, voltage surge resistance), MagForceX® Innovation Center – customer-specific development of magnet wire solutions, Wrapped Magnet Wire production (overwrapped magnet wire), Chemical processing (ISO 9001 certified)
- Materials
- Copper (High Conductivity Copper Rod and Wire), Copper (film-insulated conductors for CTC), Enamelled Wire/Magnet Wire (Magnetemp®, Magnesol®, Magnebond®), Continuously Transposed Cable (CTC), EnduroTemp® 260+, HVWW® High-Voltage Magnet Wire, UltraShield® Plus, Wrapped Magnet Wire
- Certificates
- ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, IATF 16949:2016, TISAX, UL (OBMW2 E518022), UL (OBMW2 E45523), Science Based Targets (SBTi), JISHA OHSMS, ISO 9001, ISO 14001, ISO 45001, IATF 16949, UL (OBMW2), Other (JISHA OHSMS)
- Founded
- 1930
- Employees
- 3000+ (in 11 countri
- Industries
- Automotive (electrification, OEMs), Energy (transformers, generators, renewables), Transportation (aerospace, marine, e-mobility), Industrial (electric motors, welding, HVAC, automation), Commercial/Residential (electric motors, household appliances, HVAC)
- 01
Procurement of high-conductivity copper (Copper Rod and Wire)
- 02
Drawing of copper wire
- 03
Enamelling/Film insulation (e.g. Magnetemp, Magnesol, Magnebond)
- 04
CTC transposition and overwrapping with insulating material
- 05
Testing and packaging (take-back program)
- 06
Worldwide shipping
Materials & Processes
Copper (High Conductivity Copper Rod and Wire)
High-conductivity copper rod and wire as input material, produced in-house at the Bramsche site.
Enamelled Wire/Magnet Wire (Magnetemp®, Magnesol®, Magnebond®)
Film-insulated winding wire in temperature classes from 155 °C to 220 °C for motors and transformers.
Continuously Transposed Cable (CTC)
Rectangular, film-insulated individual conductors, transposed and overwrapped with insulating material, temperature classes 120–200 °C, for transformers and generators.
EnduroTemp® 260+
Magnet wire for operating temperatures up to 260 °C with increased current density and fast heat dissipation.
HVWW® High-Voltage Magnet Wire
PDIV- and corona-resistant magnet wire for 220 °C/240 °C+ in traction and hybrid motors.
UltraShield® Plus
Inverter-compatible magnet wire (200 °C) with increased voltage surge resistance for automotive, industrial and HVAC applications.
Wrapped Magnet Wire
Magnet wire overwrapped with insulating material, among others manufactured in Kameyama (Japan).
Locations
Bad Arolsen
DEMagnet Wire Plant / MagForceX® Innovation Center (Europe)
- Materials
- Copper; Magnetemp®, Magnesol®, Magnebond® enamelled wires
- Enamelled wire production
- MagForceX® Innovation Center
Bramsche
DEMagnet Wire Plant, production of high-conductivity copper rod and wire
- Materials
- Copper (High Conductivity Copper Rod and Wire)
- Copper rod/wire production
- Enamelled wire production
Fort Wayne, Indiana
USMagnet Wire Plant and MagForceX® Innovation Center, chemical processing
- Materials
- Copper
- Chemical processing (ISO 9001 certified)
Quattordio
ITMagnet Wire Plant
- Materials
- Copper
Kameyama
JPMagnet Wire Plant (also Tokyo, Hiratsuka, Nagoya), Wrapped Magnet Wire
- Materials
- Copper
- Wrapped Magnet Wire production
Suzhou
CNMagnet Wire Plant / MagForceX® Innovation Center
- Materials
- Copper
Components & Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Magnet wire production (enamelled wires, e.g. Magnetemp, Magnesol, Magnebond)Plastics | – | – | – | – | Copper |
| Continuously Transposed Cable (CTC) production – film-insulated rectangular conductors, overwrappedPlastics | – | – | – | – | Copper |
| EnduroTemp® 260+ magnet wire production (260 °C, increased current density, fast heat dissipation)Plastics | – | – | – | – | Copper |
| HVWW® high-voltage magnet wire production (240°C/220°C+, PDIV- and corona-resistant)Plastics | – | – | – | – | Copper |
| UltraShield® Plus magnet wire production (200 °C, inverter-compatible, voltage surge resistance)Plastics | – | – | – | – | Copper |
| MagForceX® Innovation Center – customer-specific development of magnet wire solutionsEngineering | – | – | – | – | Copper |
| Wrapped Magnet Wire production (overwrapped magnet wire)Plastics | – | – | – | – | Copper |
| Chemical processing (ISO 9001 certified)Surface | – | – | – | – | Copper |
| Production of high-conductivity copper rod and copper wire (Copper Rod and Wire)Forming | – | – | – | – | Copper |
| Vertically integrated magnet wire manufacturing, 420,000 MT global production capacityPlastics | – | – | – | – | Copper |
Additional services
Reference customers
Quality & Certification
The plants are certified to ISO 9001, ISO 14001 and ISO 45001; automotive sites are additionally certified to IATF 16949 and assessed under TISAX. Product-specific UL approvals (OBMW2 E518022 / E45523) and SBTi-validated climate targets are in place.
| Evidence | Bad Arolsen | Bramsche | Quattordio | Suzhou | Kameyama | Kuala Lumpur |
|---|---|---|---|---|---|---|
| ISO 9001 | ||||||
| ISO 14001 | ||||||
| ISO 45001 | ||||||
| IATF 16949 | ||||||
| TISAX | ||||||
| UL (OBMW2) | ||||||
| Other (JISHA OHSMS) |
History
- 1930
Founding of Essex Wire Corporation.
- 1954
Founding of Superior Cable.
- 1965
44 plants in North America, revenue of USD 355 million.
- 1999
Merger of Essex Wire and Superior Cable to form Superior Essex.
- 2008
Acquisition by the Korean LS Group for approx. USD 900 million.
- 2018
PowerWise Cable wins Top Product of the Year Award (4PPoE); Living Product Challenge certification.