If you're looking to improve your control systems, one question tends to come up fairly early on: can we upgrade what we’ve got, or do we need to start from scratch with a new, bespoke panel?
There’s no one-size-fits-all answer. It really comes down to the condition of your current setup, what you need it to do now (and in the future), and how well it can support your operations going forwards. In this article, we’ll explore the key factors to consider when weighing up an upgrade versus a bespoke replacement.
Understanding your system’s current condition
Before making any decisions, it’s worth carrying out a thorough assessment of your existing control panel. This should look at:
- How old the components are and whether they’re still readily available
- The physical condition of the enclosure and wiring
- Whether it’s performing reliably under the current load
- How it holds up against today’s safety standards
- Whether there’s room for future expansion or reconfiguration
- The availability (and accuracy) of drawings or documentation
If the panel is in decent shape and has scope for integration or reconfiguration, an upgrade may be a cost-effective and practical choice. But if it’s starting to show its age, or simply isn’t suited to the demands of your operation, investing in a new panel might offer far more value in the long run.
The Interpanel team can help you identify what the right route is for you. Get in touch today to schedule a survey or to discuss your requirements.
Time to upgrade?
Upgrading an existing panel is often the right route when your existing infrastructure is relatively modern and the changes you need are more evolutionary than revolutionary. It’s a good option if:
- You’re adding new circuits, controls, or automation features
- Some components need replacing, but the overall design still works
- You’d like to improve energy efficiency with variable speed drives (VSDs) or monitoring
- Safety circuits need bringing in line with updated standards
- Your drawings need a refresh, whether that’s digitising them in E-Plan or making updates
Upgrades can also include refurbishment: cleaning, re-labelling, reorganising cabling, or adding PLC and HMI integration to bring your system in line with current tech. Services like thermal imaging surveys and condition-based assessments can also help identify issues early and reduce unplanned downtime.
The case for replace
In many cases, particularly when planning major changes to operations or processes, a brand new, bespoke control panel will just makes more sense. A new build is usually the best route if:
- The current panel is outdated, overcrowded, or non-compliant
- Your control system needs to support complex or highly automated processes
- You require a change in form factor (e.g. wall-mounted to floor-standing)
- The existing panel no longer meets environmental requirements (e.g. IP rating or ATEX compliance)
- There’s a need for standardised documentation, traceability, and validation testing
At Interpanel, we design and build custom electrical control panels to meet your exact requirements, whether it’s industrial machinery, HVAC systems, lighting control, or full-scale process automation.
Every panel we produce is tailored from the ground up, with intelligent layouts, high-quality components, and durable enclosures suitable for your operating environment. We also welcome client-supplied components and ensure seamless integration with your wider systems.
Which path is right for you?
Ultimately, the decision to upgrade or replace your control panel should always be based on what gives you the safest, most efficient, and most reliable outcome – not just today, but over the long term.
If you’re unsure which way to go, Interpanel is happy to help. Whether your system needs a light refresh or a full redesign, we’ll work with you to understand your requirements and recommend the right approach. Contact us today to get started.