Industrial electrical panels: what they are, what they do, and how they are built

Discover the strategic role of industrial electrical panels in automation and energy distribution systems

Industrial electrical panels are essential devices for controlling, protecting, and distributing electrical energy within production plants, infrastructure, and automated systems. Although their operation often takes place behind the scenes, their impact on efficiency, safety, and operational continuity is enormous.

Industrial electrical panels: definition and functions

An industrial electrical panel is a metal enclosure housing electromechanical devices such as circuit breakers, disconnectors, relays, PLCs, transformers, contactors, and fuses. Its purpose is to distribute, control, and protect electrical energy within a facility.

In industrial settings, the panel is designed to withstand harsh environmental conditions, ensure operator safety, and manage complex electrical loads reliably and continuously.

Main types of industrial panels

• Distribution panels: manage energy distribution to different areas of the facility.
• Automation panels: integrate PLCs and devices for automatic process control.
• Control panels: allow manual or remote operation of machinery.
• Power centers: handle large loads, often in medium or low voltage.

Why they are so important in industry

Without an efficient control system, an industrial plant risks malfunctions, energy losses, and costly production stoppages. Industrial electrical panels ensure:

• Safety: by separating and protecting electrical circuits.
• Reliability: distributing energy in a balanced and constant way.
• Efficiency: enabling monitoring and preventive maintenance.

Phases of building an industrial electrical panel

The construction of an industrial panel follows a rigorous process that starts from the customer’s needs and results in a customized solution:

1. Analysis and design

It begins with the load sizing, analysis of the installation environment, and applicable regulations (such as CEI and IEC standards). The electrical project is developed using CAD software and digital systems.

2. Component selection

Based on the system architecture, certified components are selected to ensure compatibility and durability. The choice of brands and materials influences the overall quality of the system.

3. Wiring and assembly

Each wire, terminal, and device is installed according to the electrical diagrams. The wiring must meet precise standards to withstand vibration, dust, humidity, and temperature changes.

4. Testing and commissioning

Before delivery, the panel undergoes insulation tests, functional verification, and safety checks to ensure it is fit for use.

Standards and certifications

Industrial electrical panels must comply with applicable European standards, including:

• CEI EN 61439: for low voltage switchgear and controlgear assemblies
• CEI 64-8: electrical installations
• Machinery Directive 2006/42/EC: if integrated into machines

A reliable manufacturer ensures full regulatory compliance and provides all required documentation: wiring diagrams, CE certification, and user manual.

2025 trends: sustainability, digitalization, and modular design

The industrial electrical panel sector is evolving toward more digital and sustainable solutions. Key emerging trends include:

• Remote monitoring and IoT: to track component status in real time
• Predictive maintenance: enabled by integrated sensors and AI
• Low environmental impact materials: to reduce the ecological footprint
• Modular design: allowing system upgrades without full replacement

According to a recent study by Markets and Markets, the market for energy control and distribution systems will continue to grow, driven by the energy transition and industrial process digitalization.

When to choose a custom electrical panel

Not all facilities can rely on standard solutions. Customization is often essential when dealing with:

• Critical environments (dusty, humid, corrosive)
• Specific safety or signaling requirements
• Centralized multi-site control systems
• Integration with SCADA or BMS systems

Choosing a specialized partner for custom industrial electrical panels ensures a precisely built product that optimizes energy use, simplifies maintenance, and improves overall system reliability.