Why Control Panel Design Is Key to Industrial Automation

In every industrial automation system, one element quietly controls it all: the control panel. Often tucked away in a plant room or mounted beside production machinery, this is the “command centre” that coordinates motors, sensors, conveyors, and packaging equipment.

When control panel design and manufacture are done well, the result is a reliable, safe, and efficient production line. When neglected, the consequences can include downtime, safety risks, compliance failures, and costly repairs.

In this guide, we’ll explain what makes a great control panel, how UK standards apply, and why food manufacturers, in particular, need designs that combine precision engineering with hygienic construction.

What Is a Control Panel in Industrial Automation?

A control panel encloses housing electrical components that manage and monitor machinery and processes. It distributes power, processes signals, and executes commands from automation software.

Typical components include:

• PLCs (Programmable Logic Controllers) — control machine sequences.
• Contactors and relays — switch high-power circuits safely.
• Power supplies and breakers — protect against overloads and faults.
• HMI (Human-Machine Interface) — operator screens for monitoring and control.

In food manufacturing, control panels integrate with inspection systems, conveyors, weighers, and packaging lines, ensuring the entire process syncs.

The Importance of Quality Control Panel Design

Good control panel design is about more than neat wiring; it’s about delivering:

• Reliability — components are logically arranged and protected, minimising failure risk.
• Maintainability — labelled wiring, clear schematics, and accessible layouts make fault-finding faster.
• Compliance — meeting legal safety requirements under UK and international standards.
• Efficiency — panels that integrate with automation systems enable energy-saving and process optimisation.

UK Compliance & Standards for Control Panels

In the UK, industrial control panels must meet:

• BS EN 61439 — Low-voltage switchgear and controlgear assemblies, covering design, testing, and safety requirements.
• BS 7671 — IET Wiring Regulations for electrical installations.
• UKCA marking — post-Brexit equivalent of CE marking, required for panels sold in Great Britain.
• Hygiene compliance — in food factories, stainless steel enclosures, smooth finishes, and IP65/IP66 ingress protection are critical to withstand washdowns.

Failure to comply can lead to legal action, invalidated insurance, and failed audits.

Designing for Food Manufacturing Environments

Food production brings extra challenges for control panel design:

• Washdown resistance — IP-rated enclosures that protect against water ingress.
• Segregated wiring — separation of power and control circuits to minimise interference.
• Temperature control — fans or air-conditioning to protect sensitive electronics.
• Operator ergonomics — placing HMIs at a comfortable height for staff use.

Well-designed panels reduce contamination risks, make cleaning easier, and ensure long service life in demanding environments.

Real-World Case Snapshots

Bakery automation upgrade

• Challenge: Fault diagnosis on old panels was slow and often required external call-outs.
• Solution: Installed PLC-based control panel with touchscreen HMI and remote access.
• Impact: Reduced fault diagnosis time by 50%; allowed the engineering team to resolve 70% of issues without leaving the office.

Snack packaging line

• Challenge: Multiple outdated panels cluttering the production floor.
• Solution: Consolidated into a single, custom-built enclosure integrating all line controls.
• Impact: Freed up 4m² of floor space, improved safety compliance, and simplified maintenance.

Dairy processing plant

• Challenge: The relay-based control system was unreliable and lacked data logging.
• Solution: Replaced with PLC/SCADA-integrated panel with full HACCP data capture.
• Impact: Reduced downtime by 18% and provided complete production traceability for audits.

The Link Between Control Panels and Automation Performance

The control panel directly affects:

• Machine response times — faster communication between PLC and machinery.
• Integration — linking production equipment with ERP/MES for real-time performance tracking.
• Scalability — allowing future automation upgrades without costly redesigns.

A well-built panel is not just a short-term solution; it’s an investment in long-term production efficiency.

Choosing the Right Control Panel Partner

When sourcing a partner for control panel design and manufacture, look for:

• Industry-specific experience — especially in food manufacturing and high-care environments.
• Full in-house capability — design, build, test, and install under one roof.
• Compliance expertise — knowledge of UKCA, BS EN 61439, and BS 7671.
• PLC/SCADA integration skills — experience with major automation platforms.
• After-sales support — for servicing, modifications, and emergency repairs.

📌 Our website offers more information on how we can help in these areas:

• Process & Control Automation
• Machinery Maintenance
• Industrial Electrical Services

10 Questions to Ask Before Commissioning a Control Panel

1. What standards do you design to?
2. Can you provide UKCA certification?
3. Which PLC brands do you support?
4. How do you ensure hygiene compliance?
5. Can the panel integrate with our current automation?
6. What testing do you carry out before delivery?
7. Do you provide wiring diagrams and schematics?
8. What’s the expected lead time?
9. Can you include remote monitoring capability?
10. What after-sales support do you provide?

How FESS Group Delivers Control Panel Projects

FESS Group provides:

• Complete design, manufacture, and installation of industrial control panels.
• Expertise in hygienic, high-reliability designs for food manufacturing.
• Proven PLC and SCADA integration for full automation capability.
• Audit-ready documentation, certification, and operator training.

By combining electrical engineering expertise with practical knowledge of the food industry, we deliver control panels that last, perform, and comply.

Next Steps

• Save our Control Panel Specification Checklist below.
• Book a control panel health check to assess compliance and performance.

FAQs

What is a control panel in industrial automation?
An enclosure housing electrical components that control and monitor industrial machinery.

What UK standards apply to control panels?
BS EN 61439, BS 7671, and UKCA marking requirements.

How do I ensure my control panel is food-safe?
Use stainless steel enclosures with suitable IP ratings, and ensure designs allow for easy cleaning.

Can a control panel be upgraded without replacing the whole system?
Yes — upgrading PLCs, wiring, or HMIs can extend lifespan and improve performance.

Do you offer both design and maintenance services?
Yes — we provide full lifecycle support from concept to maintenance.

✅ Control Panel Specification Checklist

1. Define Your Requirements

☐ Identify all equipment and processes the panel must control.
☐ Determine PLC, HMI, and SCADA requirements.
☐ Specify required inputs/outputs (I/O count).
☐ Consider future expansion or system upgrades.
☐ Set project objectives (e.g., faster fault diagnosis, remote access, compliance).

2. Compliance & Standards

☐ BS EN 61439 — low-voltage switchgear and controlgear assemblies.
☐ BS 7671 — IET Wiring Regulations.
☐ UKCA marking for Great Britain compliance.
☐ CE marking if exporting to the EU.
☐ Food industry hygiene requirements (IP65/IP66, stainless steel enclosures).

3. Design Specifications

☐ Clear, accessible layout for components.
☐ Labelling for all terminals, wires, and devices.
☐ Segregation of power and control wiring.
☐ Adequate cooling/ventilation or air-conditioning.
☐ Ergonomic HMI placement for operators.

4. Integration Requirements

☐ Compatibility with existing automation systems.
☐ MES/ERP connectivity for data and performance monitoring.
☐ Integration with safety circuits and emergency stops.
☐ Provision for remote access and monitoring.
☐ Cable routing and interface with plant infrastructure.

5. Testing & Commissioning

☐ Electrical continuity and insulation resistance tests.
☐ Functional testing of all control sequences.
☐ Verification of safety circuits.
☐ Load testing under simulated production conditions.
☐ Documentation of test results for compliance records.

6. Documentation & Training

☐ Full wiring diagrams and schematics.
☐ Panel layout drawings.
☐ Operation manuals and component datasheets.
☐ Maintenance schedule.
☐ Operator and maintenance team training sessions.

7. Ongoing Maintenance

☐ Implement regular inspection intervals.
☐ Keep critical spare parts in stock.
☐ Record all modifications and repairs.
☐ Review compliance status annually.
☐ Schedule upgrades before end-of-life component failure.

✅ 10 Key Questions to Ask Your Control Panel Supplier

☐ Which standards do you design and build to?
☐ Can you provide UKCA certification?
☐ Which PLC/HMI brands do you use?
☐ How do you ensure hygiene compliance for food manufacturing?
☐ Can the panel integrate with our current systems?
☐ What testing do you carry out before delivery?
☐ What is the lead time from order to installation?
☐ Can you provide remote access capability?
☐ What after-sales service do you offer?
☐ Can you supply case studies of similar projects?

🔍 Pro tip:

Keep this checklist in your engineering and compliance files — it will speed up specification, ensure legal compliance, and help secure long-term performance from your control panels.