As Britain’s manufacturers face rising energy costs, growing electricity demand and the need to decarbonise, factory automation is taking on a new significance. It’s not just about boosting production efficiency anymore; now, it’s about making the most of every kilowatt of power available.
Across the UK, manufacturers are investing in rooftop solar, battery storage, more efficient machinery, and electrified production processes. While these technologies often take the spotlight, it’s the electrical control systems working behind the scenes that determine how well everything operates together.
At Brierley Hill-based Banelec, this shift reflects a broader change in how manufacturers see automation. Instead of controlling individual machines in isolation, more businesses want to integrate their production equipment, utilities, and energy systems into a single, responsive system that can adapt to changing needs in real time.
Dean Banner, Managing Director of Banelec, says manufacturers are now taking a much more strategic approach to electrical control and automation.
“Five or ten years ago, most conversations centred around making one production process faster or more reliable,” he said. “Today, manufacturers are asking bigger questions. They’re looking at how their production equipment, electrical systems, and energy use can work together to make the whole factory more efficient.”
This change is driven by both economic and operational pressures.
Energy is still one of the biggest costs for many manufacturers, and the push for electrification and onsite renewables has made industrial facilities more complex to manage. Instead of treating production equipment as standalone assets, many manufacturers are now investing in integrated control systems. These systems can monitor multiple processes, balance electrical loads, and give operators a clearer view of how the factory is performing.
“Electrical control systems are now at the heart of modern manufacturing,” Banner said.
“When production lines, utilities, and power distribution are all connected through a good control system, manufacturers get a much clearer picture of what’s happening in their operations. That means they can make quicker decisions, improve reliability, and use energy more efficiently.”
This trend is also changing what manufacturers need from their engineering partners. More often, businesses are looking for specialists who can integrate older equipment with new automation technologies, rather than replacing everything at once.
For many businesses, upgrading control systems is a practical way to boost productivity and extend the life of valuable machinery.
“We’re seeing more customers wanting to modernise what they already have,” Banner added. “Replacing an entire production line isn’t always needed. Often, by upgrading control panels, adding new automation technologies, and improving how different systems communicate, manufacturers can make big improvements with much less disruption.”
As manufacturers keep investing in digitalisation, automation, and energy resilience, smart electrical control systems are becoming a key part of staying competitive in the long run.
For businesses aiming to boost productivity and manage energy better, the future of manufacturing may depend less on installing new machines and more on making sure every system in the factory works together as one.