Automation is changing how businesses work, especially in manufacturing, processing, and energy. At the heart of this change is the automation panel. These panels are the control centers that keep machines running smoothly, safely, and efficiently.
If you’re asking, “What is an automation panel?” or “Do I need one for my system?”—you’re in the right place. In this post, we’ll explore the purpose, parts, benefits, types, and buying tips for automation panels. Whether you're an engineer, plant manager, or business owner, this guide will help you make smart decisions.
What Is an Automation Panel?
An automation panel—also known as a control panel or industrial control panel—is a centralized unit that houses electrical devices used to control automated machines and systems.
These panels include components like:
Programmable Logic Controllers (PLCs)
Relays and contactors
Circuit breakers
Variable Frequency Drives (VFDs)
Power supplies
Human Machine Interfaces (HMIs)
The main job of the automation panel is to monitor, control, and manage different operations in a facility. It sends and receives signals from machines and uses logic to make real-time decisions.
Think of it like the brain of an automated system—quietly making sure everything works the way it should.
Why Automation Panels Are Essential for Industry
Automation panels play a vital role in keeping operations running efficiently. Without them, controlling complex systems would be difficult and time-consuming.
Benefits of Automation Panels:
1. Improved Efficiency
Automation panels reduce manual work. They handle repetitive tasks quickly and with high precision.
2. Better Safety
They monitor electrical faults, overloads, and emergency stops. This helps protect both workers and equipment.
3. Cost Savings
By minimizing downtime and reducing energy use, automation panels help lower operating costs.
4. Data Monitoring
Modern panels can track data in real time. This lets operators make smart decisions fast.
5. Remote Access
With HMI and SCADA systems, you can monitor and control panels from a distance—perfect for large or hazardous facilities.
6. Custom Control
Automation panels can be built to fit any process, from a small machine to a large manufacturing line.
Common Types of Automation Panels
There’s no one-size-fits-all when it comes to automation panels. The right panel depends on your application and environment.
1. Power Control Panels (PCC Panels)
These panels distribute power to motors and other equipment. They usually include breakers, meters, and fuses.
2. Motor Control Centers (MCC Panels)
MCC panels manage electric motors. They’re used in industries like water treatment, HVAC, and manufacturing.
3. PLC Control Panels
These use Programmable Logic Controllers to control systems. Great for processes that need high flexibility and customization.
4. Automation Distribution Panels
These panels split electrical power into different branches and are often used in buildings or plants.
5. VFD Panels
Variable Frequency Drive panels control motor speed and save energy. Often used in fans, pumps, and conveyors.
6. Relay Logic Panels
These use relays and timers instead of PLCs. They’re ideal for simple, repetitive tasks with fixed logic.
Key Components Inside an Automation Panel
Understanding the main components can help you troubleshoot problems or design the right panel.
1. PLC (Programmable Logic Controller)
This is the brain of the panel. It processes inputs, executes code, and sends outputs to machines.
2. HMI (Human Machine Interface)
This is the user interface. Operators use it to monitor data and control equipment.
3. Power Supply
Converts AC power into the DC voltage needed for internal components.
4. Circuit Breakers and Fuses
Protect against overcurrent, short circuits, and overloads.
5. Relays and Contactors
Used for switching high-power circuits with low-power signals.
6. Terminal Blocks
These organize wiring and help connect external devices.
7. Cooling Systems
Fans or AC units keep the panel at a safe operating temperature.
Where Are Automation Panels Used?
Automation panels are used across many industries. Here are some examples:
Manufacturing plants for process control and robotics
Food and beverage facilities for packaging and quality control
Oil and gas sites for pump control and safety monitoring
Pharmaceuticals for batch control and compliance
Water treatment for flow regulation and chemical dosing
HVAC systems for managing heating and cooling equipment
Warehousing and logistics for conveyor and sorting systems
Custom vs. Pre-Built Automation Panels
You have two options: custom-built panels or pre-engineered units. Here’s a quick breakdown.
| Feature | Custom Panels | Pre-Built Panels |
|---|---|---|
| Flexibility | High | Low |
| Cost | Higher | Lower |
| Lead Time | Longer | Shorter |
| Scalability | Built to scale | Limited |
| Best for | Unique processes | Standard applications |
Custom panels are ideal when your operations require specific features or high-level integration.
Choosing the Right Automation Panel for Your Needs
When selecting an automation panel, consider these key factors:
Type of process being controlled
Number of inputs and outputs (I/O)
Environment (humidity, dust, temperature)
Power requirements
Safety standards (UL, CE, NEC)
Future expansion needs
Working with an experienced automation integrator can make the selection process much easier. They’ll help design, build, and test the perfect panel for your business.
Automation Panel Design Tips
If you’re designing an automation panel, follow these best practices:
Plan for airflow and cooling
Keep high and low voltage separate
Label all components clearly
Allow room for future expansion
Use quality, industrial-grade components
Ensure compliance with local electrical codes
Proper panel design reduces the risk of failure, improves troubleshooting, and extends system life.
The Future of Automation Panels
Automation panels are becoming smarter. Trends include:
IoT-enabled panels for remote diagnostics
Edge computing to process data closer to the source
Wireless communication for less wiring and faster setup
AI integration for predictive maintenance
Cloud-based HMIs for remote monitoring and control
Businesses that invest in modern panels today will be better prepared for the connected future.
Ready to Upgrade Your Automation Panel?
If you want to improve safety, efficiency, and control in your facility, an automation panel is a must-have. Whether you're building a new system or upgrading an old one, the right panel can save you time and money.
? Contact us today to speak with an automation expert and get a free quote on your next panel project.
Frequently Asked Questions (FAQ)
What is an automation panel?
An automation panel is an enclosure that houses control devices like PLCs, HMIs, and relays. It automates and manages machines or processes.
What industries use automation panels?
Automation panels are used in manufacturing, energy, water treatment, food processing, pharmaceuticals, and many more.
How much does an automation panel cost?
Costs range from $2,000 to over $50,000, depending on size, complexity, and customization.
What’s the difference between a PLC panel and MCC panel?
A PLC panel controls logic and processes. An MCC panel focuses on controlling motors with starters, overloads, and circuit breakers.
Can I upgrade an old automation panel?
Yes. Old panels can be retrofitted with new components like PLCs, HMIs, and sensors to improve performance and safety.
How do I maintain an automation panel?
Regularly check wiring, clean dust filters, test breakers, and ensure cooling fans are working. Software updates may also be needed.
