Control Panel Design and Manufacture for Smarter Industrial Automation
Behind every automated process is a quiet powerhouse: the control panel. It’s the nerve centre that tells machines what to do, when to do it, and how to do it safely. But too often, control panels are outdated, overloaded, or overcomplicated, leading to faults, downtime, or even safety issues.
At FESS Group, we design and build bespoke control panels that power smarter production. From standalone units to fully integrated automation networks, our panels are built for performance, safety, and future growth and tailored to the demands of modern industrial environments.
This is the final instalment of our specialist industrial services series. It’s all about putting control back in your hands.
What Is Control Panel Design & Manufacture?
Control panel design and manufacture involves the engineering, assembly, wiring, and testing of enclosures that house:
- Programmable Logic Controllers (PLCs)
- Contactors, relays, and circuit protection
- Human-machine interfaces (HMIs)
- Safety interlocks and emergency stops
- Variable speed drives (VSDs) and power supply units
At FESS Group, our panels are built to match the specific requirements of your process, machinery, and environment. Whether food-grade, pharma-safe, or heavy industrial.
The Challenges with Poor Panel Design
Generic or outdated control panels are a hidden bottleneck in many factories. You may be experiencing:
- Frequent electrical faults or nuisance tripping
- Limited control flexibility for evolving processes
- Difficulty troubleshooting due to poor labelling or layout
- Overheating or space limitations in existing enclosures
- Non-compliance with modern safety or electrical standards
Even small inefficiencies here can create big problems across your line.
What Happens When Control Panels Let You Down?
Inadequate control systems can lead to:
- Unplanned downtime and productivity loss
- Costly damage to machinery or product
- Non-compliance with BS 7671 and safety regs
- Slowed production changes due to hardcoded logic
- Lack of data and insight from outdated controllers
Without reliable control, your automation investment can quickly lose value.
Why FESS Group Builds Better Control Panels
We don’t just assemble panels — we engineer them to work perfectly in your factory environment. Here’s how we do it:
- Full Design Consultation
We review your systems, future needs, and process goals before designing a single wire. - Bespoke Builds
From food-safe enclosures to ATEX-rated builds, we create panels that match your conditions and compliance needs. - Efficient Internal Layouts
Clearly labelled, intelligently spaced, and built for ease of access, upgrades, and maintenance. - Integrated Control Systems
Seamless connections with your PLCs, sensors, drives, and SCADA systems. - Tested and Certified
All panels are built to BS EN 61439 standards and tested in-house before installation.
Whether you’re building new or replacing the outdated, we deliver panels that perform.
FAQs
Q: Can you replicate or upgrade existing control panels?
Yes. We can redesign panels to match your current layout or upgrade legacy systems with modern, scalable options.
Q: Are your panels built to industry standards?
All panels are designed and tested to BS EN 61439 and comply with current UK industrial and electrical regulations.
Q: Do you support software and PLC programming?
Absolutely. We offer complete integration, including software logic, HMI programming, and on-site commissioning.
Q: How fast can you deliver a panel?
Lead times vary by complexity, but our in-house team ensures rapid design, build, and deployment with consistent communication throughout.
Take Control of Your Process with FESS Group
Everything starts with the right control system, from efficiency to safety. FESS Group provides smart, future-ready control panel solutions that help manufacturers take command of their production.
Let’s talk about your next panel upgrade — book a consultation today.