Essex Solutions
Essex Solutions’ manufacturing facility in Italy has become a key contributor to Europe’s energy supply chain after a deliberate shift to focus exclusively on materials for transformers and generators.
Until roughly eight years ago, the site supported multiple manufacturing segments. In 2017, the leadership team made a strategic decision to concentrate the operation solely on the energy market. Today, the location remains the only Essex Solutions plant dedicated to this product segment, a position built on technical capability, sustained investment, and disciplined execution.
“We made a conscious choice to focus, and that focus changed everything,” said Klaus Borstner, President of Europe for Essex Solutions. “By committing fully to the energy market, we were able to invest with purpose, raise our standards, and build capabilities that now place our Italian operations among the most respected in Europe.”
Since that shift, the facility has expanded its product portfolio to include highly specialized continuously transposed conductors (CTC) produced by only a limited number of manufacturers worldwide. While product reliability remains paramount—particularly in critical energy applications—the team has also continued to push innovation forward. Recent advancements include 60-micron insulation, Twin CTC, Shielded Twin CTC, and CTC solutions designed for high-voltage direct current (HVDC) applications, technologies that are helping define the next generation of energy infrastructure.
Through close cooperation with insulation partner IVA, Essex Solutions continues to advance materials performance while maintaining the consistency and reliability customers depend on.
Borstner emphasized that the operation’s current position is the result of long-term execution rather than short-term market conditions. “The market dynamics are favorable today, but we would not be able to benefit from them without the improvements made over the past several years,” he said. “Upgrading equipment, strengthening quality standards, and operating at the highest level around the clock created the foundation we rely on now.”
Those efforts were recently marked by a production milestone, as the team produced and sold 12,000 metric tons (MT) over the past year, the highest total in the site’s history. Over the last decade, improvements in machine efficiency have nearly doubled output.
Looking ahead, Essex Solutions is preparing for its next phase of expansion at the location. Plans are in place to increase capacity to 20,000 MT—approximately 45 percent growth—supported by a structured plan to nearly double the workforce on site.
“Our customers are planning years ahead, and they are counting on us to grow with them,” Borstner said. “Because of the work already done, we are ready for what comes next. The best is yet to come.”
As demand for energy infrastructure continues to rise, Essex Solutions’ Italy operations are positioned to play an increasingly important role in supporting Europe’s long-term energy needs.
