Electrical control panels are at the heart of many industrial and commercial operations, and their performance has a direct impact on efficiency, reliability and safety.
While a well-built panel can provide many years of service, evolving operational demands, changes in technology, and updates to safety standards mean there often comes a point where a control panel upgrade becomes worthwhile.
Here are six indicators that your existing system may benefit from a control panel upgrade:
1. Your equipment has grown, but the panel hasn’t evolved
As your business operations expand, through the addition of new circuits, automation, or process changes, your control panel needs to reflect those developments. Whether you’re increasing production, diversifying machinery, or introducing new functionality, a properly updated control panel will ensure your electrical infrastructure keeps pace with your growth, supports safe operation, and avoids overloading.
2. Component availability is becoming a challenge
Many older panels rely on components that are now obsolete or difficult to source. While systems may continue to function, sourcing replacement parts can become problematic and cause delays. Upgrading provides the opportunity to standardise with modern, widely available components, making maintenance easier and reducing risk of downtime.
3. Your panel isn’t as energy efficient as it could be
Improving energy performance is often a key driver for modernisation. Variable speed drive (VSD) upgrades, for instance, can significantly improve motor efficiency and reduce energy consumption across systems. Combined with better thermal management, power factor correction, and energy monitoring, modern panels help support both sustainability goals and cost efficiency.
4. The system would benefit from modern control and diagnostic tools
If your current setup doesn’t incorporate modern control and monitoring technologies, there’s significant scope for improvement. PLC and HMI integration brings intuitive, responsive control while enabling real-time diagnostics. In addition, thermal imaging surveys can be used to detect early signs of overheating or electrical faults, helping to prevent unplanned downtime and improve maintenance planning.
At Interpanel, we also bring in digital schematics with tools like E-Plan, which improves clarity and ease of future modifications, whether you’re updating legacy designs or converting paper copies to digital format.
5. Maintaining high standards of safety and compliance
Control panels must continue to meet evolving UK safety standards. Upgrades can include the design and installation of compliant safety circuits, with full documentation, to support safe working practices and legal obligations. Whether you’re improving emergency stop systems, interlocks, or safety relays, it’s essential your panel reflects current best practice.
6. Your control panel no longer reflects best practice
Wear and tear over time can affect both the functionality and appearance of a control panel. Refurbishment – such as cleaning, rewiring, relabelling, or replacing components – can significantly improve usability, reduce errors, and extend service life. A clean and logically arranged panel allows for better safety and easier troubleshooting, particularly in high-pressured or regulated environments.
Making a considered control panel upgrade
Upgrading an electrical control panel is an opportunity to align your system with your current operational needs, safety requirements, and long-term business goals. With the right expertise, modernisation can improve energy performance, enhance control, and provide a more resilient and user-friendly system.
From one-off upgrades to full system modernisation, Interpanel ensures your control panels evolve with your business. Speak to our team today to schedule a survey or discuss your upgrade requirements.