Brierley Hill wire manufacturer powers ahead with energy cost savings

A leading manufacturer from Dudley borough has cut its energy costs by 25% with grant support from Business Growth West Midlands in Dudley.

Alloy Wire International (AWI), which produces high-performance round, flat and profile wire for more than 15 global sectors, made use of UK Government funding on offer via Dudley Council to invest in solar panels for its factory in Brierley Hill.

Finance director Adam Shaw reached out to Business Growth West Midlands (BGWM) in Dudley for support after the firm encountered a four-fold increase in its energy costs due to rising wholesale electricity prices across Europe.

Alloy Wire International’s chairman Mark Venables, managing director Tom Mander, finance director Adam Shaw, and technical director Andrew Du Plessis outside their factory in Brierley Hill (left to right).

BGWM in Dudley adviser Donna Watkins worked closely with the company to carry out a detailed business review and develop an action plan.

Following an energy audit with ProEnviro, several straightforward improvements were recommended, including an upgrade to the plant’s lighting system, which is now fully LED compared to 70% previously.

The most significant change was the installation of 425 solar panels on the roof of their factory by Smart Solar. The solar panels supply all of their output directly to the plant’s furnaces, which must operate continuously to avoid damage.

To make these improvements more affordable, AWI received the Dudley Net Zero Grant, which provides 50% matched funding for investment in energy efficiency measures through the UK Shared Prosperity Fund.

The business has now reduced its energy costs by approximately 25%, a crucial saving amid challenging market conditions.

The 425 solar panels on the roof of Alloy Wire International’s factory in Brierley Hill, part-funded through the Dudley Net Zero Grant.

AWI have also benefited from the Dudley SME Grant, which provided match funding for a specialist linishing machine worth nearly £60,000. The machine produces smoother, high-performance wiring for use in tougher conditions.

This investment was vital to meet the requirements of a major automotive client, helping AWI to process bigger orders at the factory despite the rising cost of raw materials.

The firm sells to more than 60 countries around the world, with exports now accounting for 55% of its £17.5m annual turnover.

Daniel Holyhead, wire technician at Alloy Wire International, operating their new specialist linishing machine, which was part-funded by the Dudley SME Grant.

Adam Shaw, finance director of Alloy Wire International, said:

“Sustainability is a big focus for our business, and we are keen to lead the world when it comes to manufacturing wire that has a minimal impact on the environment. 

“The support we have received from Business Growth West Midlands in Dudley and Dudley Council has helped us accelerate several investments in more efficient LED lighting, solar power and new linishing capability.

“This is a real win-win for AWI. We are boosting our sustainable performance, whilst also reducing operating costs, meaning we can remain competitive with our international rivals and can channel some of the savings into staff development and new equipment.”

Donna Watkins, Business Growth West Midlands in Dudley adviser, said:

“Alloy Wire International is just the kind of forward-thinking, high-performing business we’re proud to support through the Business Growth West Midlands programme.

“Their ambition to lead on a global scale, combined with a relentless commitment to innovation - from advanced alloys to cutting-edge production techniques - makes them a stand-out manufacturer in the region.

“It’s been inspiring to work alongside a team so driven to grow, not just in size, but in capability and sustainability. Their story is a clear example of how strategic support, and a growth mindset can deliver real impact.”

Councillor Simon Phipps, cabinet member for economy and infrastructure at Dudley Council, said:

“Our grants programme continues to drive growth across Dudley borough, helping local businesses to create new jobs, reduce their energy costs, and invest in cutting-edge machinery that boosts their productivity.

“It’s fantastic to see the measurable impact these grants are having, especially in our manufacturing sector. Alloy Wire International is a really innovative business and I’m glad we’ve been able to support their progress.

“If your business needs that extra bit of investment and support to get to the next level, please do get in touch with our advisers. They will walk through the many ways that they can help you to fulfil your ambitions.”

Melissa Dunn, project officer with Dudley Council’s economic growth team, and Adam Shaw, finance director of Alloy Wire International, with the business’s new solar-powered generators.

Business Growth West Midlands in Dudley have supported more than 600 businesses across Dudley borough with a range of measures.

Their package of support includes advice from local business growth advisers, grant programmes, innovation support and assistance for entrepreneurship and start-up businesses.

More details on Business Growth West Midlands in Dudley can be found at www.businessgrowthwestmidlands.org.uk.

Businesspeople who are interested in receiving support should complete the enquiry form on the BGWM website, or call Dudley Business First on 01384 812001.

Businesses that are looking to improve their energy efficiency can benefit from a new grant programme introduced this year. The Business Energy Advice Service is managed by Business Growth West Midlands.