How-to: Optimise Your Control Panel Design for Better Performance
At T-T Controls and Automation®, we understand that a well-designed control panel is vital to operational efficiency, long-term reliability, and compliance with the highest industry standards. All of our standard DOL and ASD control panels are manufactured in-house, undergoing rigorous testing procedures to ensure peak performance and durability. For more complex requirements, our bespoke control panels are tailored to suit your specific application, offering flexibility without compromise.
In this guide, our engineering experts share key principles for optimising your control panel design, drawing on decades of experience in supplying reliable, scalable solutions for industrial, municipal, and commercial applications.
1. Core Principles of Optimised Control Panel Design
At T-T, we take a modular design approach to streamline assembly, simplify upgrades, and reduce lead times. By standardising layouts across our product range, we maintain consistency, quality, and efficiency.
Our space-saving panel designs allow for more compact installations without sacrificing functionality, especially valuable in constrained or retrofit environments.
T-T Approach:
- Modular designs for enhanced scalability and serviceability
- Consistent layout standards to reduce installation errors
- Compact, efficient enclosures built for demanding environments
2. Smart Component Selection and Strategic Placement
We carefully select every component in our control panels for performance, reliability, and compatibility. T-T uses slimline, high-efficiency components and groups them based on functionality and thermal output to ensure optimal airflow and thermal management.
Our engineers take into account both current demand and future expansion when placing and specifying components—key to a system that performs from day one and is ready for tomorrow.
Included in Every T-T Panel:
- Compact, energy-efficient devices
- Logical grouping to optimise cooling and service access
- Built-in thermal pathways for enhanced airflow management
3. Wiring Techniques that Enhance Reliability
At T-T, we apply control panel wiring optimisation as standard, using structured point-to-point wiring, engineered cable routing, and spring-cage terminals for secure, maintenance-friendly connections.
Our experienced technicians follow strict cable management best practices, ensuring every panel is not only easy to service but built to last.
T-T Quality Assurance:
- Clean, labelled, and easily traceable wiring routes
- Colour-coded and numbered conductors for clear diagnostics
- Professional finishing ensures long-term durability and safety
Learn more about Quality Assurance.
4. Harnessing Advanced Technology in Panel Design
We leverage the latest 3D control panel design software and automated optimisation tools to streamline the design and build process. These technologies allow us to validate layouts, simulate airflow, and ensure the best use of space before manufacturing even begins.
T-T also offers diagnostic integration capabilities that make maintenance easier and downtime shorter.
What You Can Expect:
- Accurate 3D previews and virtual simulations
- Smart layout optimisation for thermal and spatial performance
- Optional diagnostics and remote monitoring features
5. Designing Future-Proof Panels
Our control panels are built with expansion and scalability in mind. We allow for additional I/O, spare terminal capacity, and modular additions where needed, helping your system grow with your operation.
Whether it’s a standard DOL control panel or a fully custom ASD solution, T-T ensures your investment is ready for change.
Built-In Flexibility:
- Reserved space for future component additions
- Scalable hardware platforms
- Universal enclosure designs for long-term adaptability
6. Safety and Compliance at the Core
Safety is a priority at every stage of T-T’s panel design process. We ensure all panels are compliant with relevant standards such as BS EN 61439, and we include full labelling and documentation to assist with commissioning, maintenance, and audits.
Where required, we integrate surge protection, emergency stop and critical safety systems, and isolation features to meet your specific health and safety needs.
Talk to us for any specific Performance Level (PL) or Safety Integrity level (SIL) required.
7. Maximising Panel Performance
Our panels are designed to operate in tough environments. We incorporate performance optimisation strategies to reduce heat buildup, limit electromagnetic interference (EMI), and improve accessibility for fast servicing.
This means less downtime, lower operating costs, and higher overall industrial automation efficiency.
Performance Enhancements Include:
- Passive and active cooling options
- Isolated cable routing to minimise EMI
- Front-facing components and removable plates for easy access
Why Choose T-T?
With every T-T panel, you're not just investing in a product—you're gaining a partner with proven experience in designing efficient, future-proof control solutions. Whether you need a compact DOL panel or a fully engineered ASD control system, we ensure that each design reflects our commitment to quality, safety, and long-term value.
Looking to upgrade your control panel systems or begin a bespoke project? Speak to our expert team today to discover how T-T Controls® can deliver performance, compliance, and peace of mind—built in.