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Overview of the Global Cable Industry - Markets and Materials

Astrid Aupetit

Applied, Market Information, AMI Consulting, 1 Brunswick Square, Bristol BS2 8PE, UK

The cable extrusion industry makes up only a small part of the global plastics industry, accounting for just under 3% of plastic consumption. However, it is a high-value market, where producers commit to the industry for the long term; it is not a sector for opportunistic business.

Geographically, the market is dominated by Asia, and more specifically, China. In terms of market size by polymeric materials, Asia and Australasia accounted for 55% of the tonnage used in cable extrusion in 2018. There are around 8000 cable manufacturers in the world, with the number in China estimated between 4000 and 6000. China has not yet fully consolidated its market, but it has reduced its number of manufacturers from 7000 to around 5000. Most are small or medium-size companies.

The cable industry is a complex market segment, due to the number of applications under the main sub-segments: power and communications. Consequently, there are a large number of cable constructions, which can easily reach more than 2000 per manufacturing site. The cable business is strongly technology driven and therefore requires a good technical understanding by all the parties involved.

Electric cable constructions consist of a copper or aluminum conductor, often with steel armoring, and polymeric materials for insulation and jacketing.

Owing to the range of end-use applications, a variety of polymeric materials are used. As a result, any producers decide to specialize in only a few types of cables to reduce investment in machinery.

Further complexity arises from different national standards, which make it harder for foreign producers to enter markets if their cables do not already meet local requirements. Indeed, in Europe, standards are in place for specific cables, notably in construction (Construction Product Regulation [CPR]) and transportation, which producers have to take into account when manufacturing cables. India and China are also in the process of putting in place legislation for the construction and building sector.

Cable manufacturing involves various stages of production, including metal drawdown, compounding, insulation and sheathing material extrusion, armouring, and eventually cross-linking processes.

The three main sectors that influence the demand for cable are infrastructure, transportation, and construction. Investments in these sectors have a direct impact on a country's demand for cable. Regarding the construction sector, the current trend of urbanization is leading to larger cities, placing with greater demands on power transportation and distribution networks.

The trend toward more eco-friendly solutions for transportation such as e-mobility is also creating additional opportunities for the cable industry.

Renewable energy is also a sector with increasing demand for cable, not least as the electricity generated must feed into the power grid. Indeed, investment in renewable energies is driving particularly strong growth in the medium voltage (MV) and high voltage (HV) segments, related to energy transmission and distribution. In 2017, global cumulative installed renewable power capacity was 2179?gigawatts (GW), with wind energy representing over 23.5%.1 The Paris Agreement (2016) gathered nations to meet a level of use of renewable energies and has heightened the demand for power cables across the board.

In the Americas and Europe, demand is being driven by the need for power connection between countries and transmission efficiency. In emerging markets such as Southeast Asia and the Indian Subcontinent, rapid economic development and urbanization are key growth drivers.

According to the United Nations Organization,2 around 60% of the world population will be living in urban areas by 2030 and 68% by 2050, leading not only to new network needs but also to the renovation of existing infrastructure.

In China, the recent slowdown is not expected to last too long as long as government investment picks up.

Investment in construction is forecast to grow globally at an average rate of 3% per year until 2022 (Figure 1.1). This growth is spread quite evenly between civil engineering, and nonresidential and residential construction, with the latter seeing the highest investment level. Unsurprisingly, however, cable demand growth is not homogeneous across regions.

Rapid economic development and urbanization, especially in Southeast Asia, is driving strong construction investment growth. In more mature markets such as Europe and North America, growth is typically in the low single digits. Currently, the level of urbanization in Asia is 50%, while it is 82% in North America and only 43% in Africa.

Another important and bellwether sector is automotive. Global automotive investment growth is forecast to be marginally slow in 2019-2022 compared to the previous years (Figure 1.2). However, structural trends such as the development of electric vehicles and the trend toward e-mobility are having a positive effect on the cable sector.

Figure 1.1 Investment in construction in 2013-2022 worldwide.

Figure 1.2 Global evolution of automotive production in 2013-2022.

Major concerns for the industry include a range of geopolitical uncertainties. Chief among them are US-China trade frictions and Brexit. Such events are, at best, causing investment to be merely delayed.

1.1 Demand for Polymeric Material

In 2018, Asia and Australasia accounted for almost 60% of global demand, with China alone representing just over 40%. Europe (17%), North America (12%), and Middle East and Africa (10%) all had double-digit shares. South America represented just 2% of the global market (Figure 1.3).

1.1.1 Main Companies Profile

The cable industry is spread worldwide, although it is dominated by a few companies that are present on most continents.

Figure 1.3 Global usage of polymeric materials by region. Source: AMI Consulting 2019.

1.1.1.1 Prysmian

Prysmian is the largest cable manufacturer in the world by revenue. Since the acquisition of General Cable in 2018, their combined sales amounted to ?10.158?billion in the year. The company was created in 2005 in Milan, Italy, by Goldman Sachs from the cables and systems division of Pirelli & C. S.p.A. and the group was created in 2011 after Prysmian acquired Draka. Prysmian Group is a public company and offer products and solutions in power grids (including submarine and HV and extra high voltage [EHV] cable systems), oil and gas, telecoms (optical and copper cables), construction and infrastructure, transportation and mobility, and industrial applications. It serves the energy, military, mining, nuclear, and renewable energy industries. The group now has 112 plants in 50 countries. Overall, Prysmian has 29?000 employees not just in the manufacture of cables, but also in cable assembly and wiring and cable systems. Sales are spread as follows: 58% Europe, Middle East, and Africa; 24% North America; 8% Latin America; and 10% Asia Pacific.3 They also operate a network of 25 R&D centers globally.

1.1.1.2 Nexans

Nexans is the second largest cable producer worldwide. Its headquarters are located in Paris, France, and the company has 51 plants in 34 countries, most of them in Europe. It employs 27?000 people.

Nexans manufactures power (low voltage [LV] MV, HV, EHV), telecom, industrial, and transportation cables as well as cable solutions (i.e. harnesses). It supplies the energy, transportation, telecom, industrial, construction, infrastructure, and aerospace industries. Nexans owns three plants in China and has managed to penetrate the Chinese market by winning projects working for the State grid. In 2018, Nexans achieved ?6.490?billion in sales (current metal price). The geographic split of revenue is as follows: 37% Europe, 14% North America, 12% Asia-Pacific, 6% Middle East, Russia, and Africa, 5% Central and Latin America (11% harness, 15% HV). The largest application segment is building and infrastructure, accounting for 43% of revenues.

1.1.1.3 Southwire

Southwire is based in Carrollton, Georgia, in the United States. Out of its 19 plants, only one is outside of North America. The company has 8000 employees and in 2017, their sales were US$ 5.5?billion. It is privately owned and is the largest North American manufacturer after Prysmian, which, thanks to the acquisition of General Cable, has increased its presence on the continent.

Southwire offers power cables (LV, MV, HV, and EHV), telecommunications cables, and industrial cables made of copper rod, aluminum, and magnetic materials.

The company also provides engineering, fabrication, and inventory management services. Southwire supplies to the building sector, utility companies, and original equipment manufacturers for the automotive, electrical, and industrial equipment industries.

1.1.1.4 Sumitomo Electric Industries

Sumitomo...