From engineering tools and automation technology to electrical components and power systems, industrial control panels sit at the heart of modern manufacturing and engineering operations. They allow engineers, system integrators, OEMs and machine builders to manage hardware and software functions reliably and efficiently.
A well-designed control panel not only improves usability but also ensures safety, reduces downtime and makes fault-finding easier. Often, you can tell at a glance whether a control panel is organised and intuitive or cluttered and inefficient.
In this article, we explore the key elements that make for a strong control panel design, and why clear labelling and durable overlays are essential for long-term reliability.
Component Placement and Layout
Control panel layouts should be logical, functional and aligned with electrical schematics. Typically, high-voltage components are placed at the top, where the main incoming power isolator is located. Power distribution breakers, fuses and terminals are arranged consistently to make fault-finding straightforward. Adequate spacing allows room for expansion and reduces heat build-up. I/O terminals and PLC racks are often positioned towards the bottom, where field instrument wiring usually enters.
This structured approach improves safety, efficiency and serviceability.
Labelling and Identification
Clear, durable labelling is one of the most important aspects of control panel design. Engineers rely on well-marked wires, breakers and terminals to reduce errors and save time during maintenance or system upgrades.
Wire labelling should follow schematic line numbers or PLC addresses for clarity. Component labelling often uses standard prefixes such as AC120 for 120VAC or DI for digital input.
At Custom Labels Ltd, we manufacture ultra-durable, under-surface printed polycarbonate control panel labels and graphic overlays. Produced in our UK facility in Somerset using premium 3M adhesives, our overlays are resistant to scratches, chemicals and saltwater. They are built to last for years in extreme environments, ensuring your critical control markings remain clear and compliant for the lifetime of the equipment.
Panel Sizing and Wireway Design
Good design also means planning for the future. Panel sizing should provide both horizontal and vertical space for additional terminals, breakers and wiring. Overcrowded panels create unnecessary heat and complicate modifications.
Wireway design should allow smooth routing of both field I/O and internal panel wiring. Proper spacing makes termination easier and provides flexibility for future upgrades.
Bringing It All Together
A well-built control panel is more than just components. It is about clarity, organisation and reliability. From logical layouts to thoughtful wire management, every design decision impacts long-term performance.
And when it comes to the finishing touch, professional industrial-grade labels and overlays make all the difference. They help engineers work efficiently, reduce downtime and ensure panels remain compliant and easy to operate, even in the harshest industrial environments.
Partner with Custom Labels Ltd
At Custom Labels Ltd, we have been supplying control panel labels and graphic overlays to machine builders, system integrators and OEMs across the UK and beyond. Our products are built to last, ensuring your control panels remain functional, professional and reliable for years to come.
If you would like advice on selecting the right materials or adhesives for your control panel labels, contact our team today. We are here to help.
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