What Makes a Good Control Panel Design?

Mar 9
3 min read

Updated: Mar 25

Industrial Control Panel Design Best Practices (UK Guide)

A well-designed control panel is critical to the performance, reliability, and maintainability of any industrial automation system.

Poor control panel design leads to:

Increased downtime
Difficult fault finding
Safety risks
Higher maintenance costs

Understanding what good control panel design looks like helps ensure your system is reliable, easy to maintain, and built for long-term performance.

What Is Industrial Control Panel Design?

Control panel design involves planning and structuring the electrical systems that control machinery and automation processes.

This includes:

Electrical schematics and layouts
Component selection
Wiring and terminal design
Integration with PLC and SCADA systems

The quality of the design directly affects how the system performs in real-world environments.

Key Elements of Good Control Panel Design

A well-designed industrial control panel should include the following:

Logical Layout & Component Placement

Components should be arranged in a clear and structured way:

Group related components together
Maintain consistent layout standards
Ensure clear separation of power and control circuits

Why it matters: A logical layout makes panels easier to understand, maintain, and troubleshoot.

Clear Labelling & Identification

Every component, wire, and terminal should be clearly labelled:

Consistent naming conventions
Clear terminal numbering
Visible component identification

Why it matters: Poor labelling increases fault-finding time and leads to costly downtime.

Structured Wiring & Cable Management

Good wiring practices are essential:

Neatly routed cables
Segregation of different voltage levels
Use of trunking and cable management systems

Why it matters: Messy wiring leads to errors, faults, and difficult maintenance.

High-Quality Documentation

A good design always includes:

Electrical schematics
Wiring diagrams
I/O lists
Component schedules

Why it matters: Without documentation, even simple faults can take significantly longer to resolve.

Standards Compliance (UK & International)

Control panels should meet recognised standards such as:

BS EN 61439
Electrical safety regulations
Industry-specific requirements

Why it matters:Compliance ensures safety, reliability, and long-term usability.

Suitable Component Selection

Components should be chosen based on:

Application requirements
Environmental conditions
Reliability and availability

Why it matters: Using the wrong components increases failure rates and maintenance costs.

Designed for Maintenance & Expansion

A well-designed panel should:

Allow easy access to components
Provide space for future expansion
Be easy to modify or upgrade

Why it matters: Systems evolve — design should support future changes.

Good vs Poor Control Panel Design

Feature	Poor Design	Good Design
Layout	Disorganised	Logical and structured
Labelling	Missing or unclear	Clear and consistent
Wiring	Messy and difficult to trace	Neat and well-managed
Documentation	Limited or missing	Complete and accurate
Maintenance	Difficult and time-consuming	Easy and efficient

The difference directly impacts downtime, maintenance, and long-term costs.

Real-World Example:

Poor Design:

Unlabelled wiring
No documentation
Difficult to trace faults

Result: Extended downtime and costly troubleshooting

Good Design:

Clearly labelled components
Structured layout
Full documentation

Result: Faster fault finding, reduced downtime, and easier maintenance

Control Panel Design Standards (UK)

In the UK, industrial control panels are typically designed to meet:

BS EN 61439 (low-voltage switchgear and controlgear assemblies)
Electrical safety standards
Industry-specific compliance requirements

Following these standards ensures safe, reliable operation and long-term system performance.

Design for New Systems vs Existing Panels

New Control Panel Design

Fully customised layout
Designed for system requirements
Scalable and future-proof

Control Panel Refurbishment

Upgrade existing panels
Improve layout and wiring
Replace obsolete components

Learn more about control panel refurbishment and upgrades

Integration with Automation Systems

A well-designed panel integrates with:

PLC programming systems
SCADA and HMI systems
Machine control systems

Ensuring the entire automation system works together efficiently

Key Takeaways:

What Good Control Panel Design Looks Like

Logical, structured layout
Clear labelling and documentation
High-quality components
Standards compliance (BS EN 61439)
Designed for maintenance and expansion

Frequently Asked Questions