Rodrigo O’Byrne

TBY talks to Rodrigo O’Byrne, CEO of Enerwire, about the company’s successes, changing product demand, and goals for the El Salvadorian market.

What have been some of the most important milestones for Enerwire since its founding?

Enerwire was founded in 1993 with a small team of three employees, producing only three products and processing about 20 tons of raw material annually. Today, after 31 years, we have grown to over 320 employees, processing approximately 8,500 tons of raw material each year. The plant can now produce 1,000 different products. Since our inception, we have fostered a culture committed to quality, earning multiple certifications across environmental standards, management systems, and product quality. We began processing copper conductors and later added aluminum 1350, bimetallic conductors in 2008, and aluminum alloy 8000 series around 2015-2016—all recognized by the US National Electrical Code. In the past five years, Enerwire has experienced significant growth, expanding exports from Central America and the Dominican Republic to now include the US, the Caribbean, and Mexico. In terms of recent developments, we have outlined a significant investment of around USD50 million to be developed over eight to nine stages. The first phase, with an initial investment of USD6 million, is already underway, and we expect it to be completed by 2025. These investments are modular, allowing us to gradually expand production areas, machinery, and processing capacity. Our current plant has become too limited for our needs, and we also have another plant in the Santa Elena, Antiguo Cuscatlán area. In total, we now operate two processing plants and four warehouses for storage and distribution, serving both El Salvador and our export markets.

What strategy has Enerwire adopted to meet product demand across different sectors?

Much of our growth has been fueled by market demand, which naturally supports a diverse range of products. The key factor is whether you have the production capacity and storage space to support this range of products. On the other hand, some of our growth has also come from strategic investments we have made. Our product catalog is organized into six main application areas: residential, commercial, industrial, renewable energy, overhead lines, and grounding applications. Each sector has specific electrical conductor requirements, with further subdivisions expanding the range. We offer around 1,000 products, not including color variations (which have specific meanings in electrical systems) or packaging options like 100m boxes or coils of 500m and 1,000m.

What are Enerwire’s main objectives with the new plant?

It will primarily focus on exports. We have already received approval for the Asset Improvement qualification from the Ministry of Economy. This is equivalent to a free trade zone but for a single producer. To benefit from this, the key rule is that the operation must be primarily export-oriented. Accordingly, our strategic plan is to gradually move all our export capacity to this new facility while keeping our current plant to continue producing for the Salvadoran market. Although the local market is still our main one, and we continue to grow within it, we see significant opportunities beyond El Salvador’s borders, specially the US, the rest of Central America and the Caribbean.

How is Enerwire integrating sustainable practices into its manufacturing processes?

Sustainability is deeply ingrained in our culture, and the implementation of responsible practices is embedded across all our operations. In 2019, we became the second company in El Salvador to achieve ISO 50001 certification, a standard focused on effective energy management. This certification confirms our commitment to systematically and efficiently managing our energy resources. In 2021, We became the first company in El Salvador to certify that 100% of our production and operations are powered by renewable energy. Over 50% of our energy is sourced from a rooftop photovoltaic solar plant, with the remaining 50% certified through the I-REC standard. Through our EnerGreen sustainability program, materials like copper, aluminum, bimetallics, and plastics are sorted and sold for reuse, re-entering a new production lifecycle. Additionally, we have produced 8 million meters of photovoltaic conductors for green energy projects across the region, the US, and the Caribbean that are currently powering clean energy on these projects.

What technological innovations has Enerwire recently implemented in its products or processes?

From an operational standpoint, we consistently strive to enhance our product offerings through innovative solutions. One example is our bimetallic conductors, known as copper-clad aluminum. Traditionally, the industry has relied on copper or aluminum conductors, but this bimetallic product combines an aluminum core with an outer layer of copper metallurgically bonded to the aluminum core. This product provides a cost-effective alternative to pure copper conductors, delivering the same connectivity benefits with reduced voltage drop, which enhances energy efficiency and minimizes transmission losses when sized properly against copper.

How does Enerwire approach partnerships in international markets?

We adopt a holistic approach to partnerships, from sourcing raw materials globally to serving our end customers. There is no local supply for manufacturing electrical conductors in Central America. Although we source some local items like packaging and office supplies, the majority of our raw materials are imported, posing significant logistical challenges. Our strategic partnership with Copperweld in the US has been instrumental in expanding our reach within the North American market, managing a significant portion of our export distribution. In regards to local partnerships, the favorable business climate in El Salvador has also allowed us to work alongside government institutions on impactful projects, showcasing the strength of public-private partnerships.

What specific job opportunities is this plant creating, and what social impact do you anticipate in the local community?

Our current team of 320 employees is vital to our operations. We see the new plant as a key development for Enerwire, with a positive social impact by creating indirect jobs during construction and direct employment once operational. We need skilled Salvadoran talent to produce world-class electrical wire and cable at our new site. This will contribute to job creation and economic development in El Salvador. We anticipate hiring around 50-60 people by mid-2025. However, once the facility is fully developed, our master plan indicates that it will employ significantly more people than our current operation.

What are Enerwire’s goals for El Salvador and the region by 2025?

The major focus is on completing the new plant, projected for mid-next year. Additionally, we are launching Industry 4.0 projects, aiming to connect all production lines to a central system for real-time production data analysis, improving decision-making. We are also in discussions with a Salvadoran company to train an AI model for internal knowledge management, helping new hires by streamlining learning processes. The new plant will integrate Industry 4.0 and 5.0 technologies. Strengthening our team and enhancing local talent is critical to delivering world-class electrical wire and cable and meeting future challenges.