Electrical Control Panel Design & System Integration
Maquina Technical Services offers bespoke electrical control panel design, automation and robotics integration services for industrial applications.
Our solutions include PLC programming, motor control systems, and fully compliant installations following IEC and EMC standards.
For any further details or to get a quote please call 01332 492625 or contact our team
To find out more about our Electrical Control Panel Design & System Integration contact us today:
Electrical Control Panel Builders
As electrical control panel design specialists we partner with leading manufacturers like Siemens, Mitsubishi Electric, and Schneider Electric to provide reliable, scalable, and efficient control systems designed to enhance productivity and reduce downtime. We focus on delivering future-ready automation solutions tailored to client needs, ensuring seamless integration and long-term support.
Maquina Technical Services can offer a wide range of electric control panel building services from bespoke one off jobs to panels manufactured in high quantities.
All our electronic control panels are built in accordance with standards;
- IEC 60204-1 safety of machinery – electrical equipment of machines – part 1: general requirements
- The low voltage directive (LVD) (2014/35/EU)
- EMC Directive (2014/30/EU)
- 13849-2 The safe design of controls systems
Building Electrical Control Panels
Once built all are UKCA marked and come with a technical file with all relevant safety information, operating & installation instruction and technical drawings.
Managing large-scale system integration projects involving diverse machinery and equipment our expertise includes overseeing complex control systems integration across multiple platforms, ensuring seamless operation between robotics, automation systems, and motor control panels.
With a focus on minimising downtime, we provide end-to-end project management from design through to commissioning. Our approach ensures compliance with industry standards and optimises performance for manufacturing automation.
Integration Solutions
Maquina Technical Services can take a design, concept or idea and build it for you.
- Tailored Solutions: We don't believe in one-size-fits-all solutions. Instead, we analyze your unique needs and existing systems to design a custom integration plan that works for your business
- Cutting-Edge Technology: We stay at the forefront of technological advancements, allowing us to seamlessly incorporate the latest control systems into your setup, ensuring you're always ahead of the curve
- Minimal Downtime: We understand that downtime means lost revenue. Our integration processes are designed to minimize disruption to your operations, so you can continue running your business without interruptions
- Compatibility Assurance: Worried about compatibility issues? Rest easy! Our team meticulously tests and fine-tunes every integration to ensure that all systems work harmoniously together
- Scalability: As your business grows, your systems must adapt. Our integrations are built with scalability in mind, so you can easily expand and upgrade without a hitch
- Expert Support: Our support doesn't end with the integration process. We offer ongoing assistance, troubleshooting, and maintenance to keep your integrated systems running smoothly
- Cost-Efficiency: Investing in new control systems shouldn't break the bank. We offer cost-effective solutions that provide maximum value for your budget
Some of the PLC's we can work with:
- Mitsubishi
- Omron
- Siemens
- Allen Bradley
- IMO
- Phoenix Contact
- Schneider Electric
- Many more
A list of full services provided by our integration department:
- Electrical control panel design
- Safe system design
- Schematic drawings
- Motor and drive integration
- Industrial Automation and robotics
- PLC programming
- CNC retrofitting
Case Study - Safety Control System for Underlay Production Machine
Industry: Manufacturing & Processing
Project: Electrical Control Panel Build, PLC Programming, and Machine Safety Integration
A UK-based flooring manufacturer purchased an underlay production machine from overseas. The equipment, comprising a foam shredder and a log moulder, was non-compliant with UK safety regulations. The machine lacked a valid UKCA mark, and its CE marking was invalid due to inadequate safety measures.
Despite the customer installing perimeter fencing and access gates, the machine’s control system did not meet PUWER (Provision and Use of Work Equipment Regulations) requirements. A comprehensive machine risk assessment identified critical safety hazards, requiring a safety-related control system to mitigate risks and achieve compliance with ISO 13849-2 standards.
Maquina Technical Services Ltd was appointed to design, build, and integrate a bespoke safety control system to ensure the machine met the necessary legal and safety requirements. Key focus areas included:
- Designing a safe control system to manage machine hazards
- Installing safety devices, including interlocking gate handles and "key in pocket" systems, to prevent unauthorised access to hazardous areas
- Building and integrating an electrical control panel with a programmable safety controller (PLC) to ensure controlled, safe operation of the machine’s motors, pumps, and hydraulics
Our solution involved implementing Euchner MGB2 interlocking door handles and Euchner CKS 2 "key in pocket" systems to control access through the machine’s gates.
Operators wishing to enter the machine perimeter must:
- Remove a CKS key, keeping it on their person
- Press an entry request button on the gate
- The system verifies that the machine is in a safe state—monitoring conditions such as heat, steam, and hydraulic activity—before unlocking the gates
Once maintenance or operational tasks are complete, operators must perform a full area sweep before exiting. This involves pressing four strategically placed reset buttons, ensuring all zones are clear of personnel. The gates can only be fully reset when the CKS key is returned to its terminal, ensuring no one remains inside the cell.
We delivered a complete, end-to-end solution, including:
- Design and build of a bespoke safety-related electrical control panel
- Installation of a Euchner MSC programmable safety controller to handle motor control, pump shutdowns, and safety device monitoring
- Integration of safety devices, including Euchner MGB2 door handle interlocks and Euchner CKS 2 key systems
- Full integration with the existing electrical system, ensuring that motors, pumps, and other key components shut down during entry procedures
- Development of a comprehensive SISTEMA report, electrical drawings, and Safe Operating Procedures (SOPs) to provide the client with a complete technical file for compliance
Maquina Technical Services Ltd focused on achieving compliance with:
- UKCA marking requirements for machinery used in the UK
- PUWER (Provision and Use of Work Equipment Regulations) for safe machine operation
- ISO 13849-2 for safety-related parts of control systems
Our machine risk assessment and SISTEMA calculations ensured that the control system met the highest functional safety standards.
Following the integration of the new safety control system, the client now benefits from:
- A machine that is UKCA compliant and PUWER ready
- A safe working environment for operators and maintenance staff
- Controlled entry and exit procedures that reduce the risk of accidents
- Full shutdown functionality, ensuring motors, pumps, and other hazardous equipment are powered down before access is granted
- Comprehensive documentation, including SISTEMA reports and technical files, for ongoing compliance
The system improves overall operational safety while maintaining production efficiency. The client can now confidently operate their underlay production line, knowing that it meets the highest machine safety standards required in the UK manufacturing sector.
At Maquina Technical Services Ltd, we specialise in delivering tailored control system solutions that ensure your machines meet UKCA marking, PUWER compliance, and functional safety standards.
Our services include:
- Electrical Control Panel Design and Build
- PLC Programming and Integration
- Machine Safety System Design
- Machine Risk Assessments
- SISTEMA Reporting
We help businesses in the UK manufacturing sector achieve safe and compliant production environments, ensuring your equipment is fit for purpose and legal to operate.
Case Study - Bespoke Control System for Improved Safety and Efficiency
Maquina Technical Services delivered a bespoke control system to eliminate a manual handling task within a client’s machinery process. The original lever’s were heavy and prior to this upgrade, one lever had sprung back under tension and hit an operator in the face. This required a hospital visit.
The project began with a comprehensive survey of the client’s manual mechanical process. Maquina Technical Services then designed a tailored solution, which was reviewed and approved by the client before implementation.
The solution involved the integration of synchronised DC-powered linear actuators to lift a heavy machine component as part of its regular operation. This replaced the previous manual system, which required operators to use heavy levers to perform the task.
At Maquina’s facilities, the control panel was precisely built to the agreed specifications, ensuring both quality and reliability. Upon completion, the system was installed on-site. The new actuators were integrated into the machine’s existing framework, making the operation faster, safer and the alignment of the loader was much better.
Throughout the project, Maquina adhered to all relevant industry standards, ensuring the highest levels of safety and compliance. These included:
- IEC 60204-1 (Safety of Machinery – Electrical Equipment of Machines)
- Low Voltage Directive (2014/35/EU)
- EMC Directive (2014/30/EU)
- ISO 13849-2 (Safety of Machinery – Safety-Related Parts of Control Systems)
The tailored solution was highly praised by both the client and their operators. By replacing manual heavy levers with synchronised actuators, the system improved operational safety and ease of use.
The bespoke control system significantly enhanced the safety of the machinery, reducing the risk of injury associated with manual handling tasks. Additionally, the automated process improved operational efficiency, leading to a streamlined workflow and reduced operator fatigue.
The client expressed satisfaction with the solution, noting its positive impact on both operator safety and machine performance. The operators particularly appreciated the simplified and safer operation of the machine, underscoring the effectiveness of the tailored solution provided by Maquina Technical Services.
For more information on our Electrical Control Panel Design & System Integration, CNC Maintenance, Servicing, Breakdown & Repair, TPM, PPM or PUWER Assessment, or if you would like to speak with one of our team please, contact us.