One-stop control cabinet manufacturing: It doesn't get any more compact than this!
Custom Control Panel Manufacturing
Mass Production
Top Priority: Compliant with Standards in Every Respect
As an esmatic customer, you can take advantage of our all-inclusive service, which includes EPLAN design, or provide us with finished design documents and commission us to build the control panel. Whatever you decide: We ensure that every control cabinet leaving our facilities is manufactured in compliance with standards. We adhere to the switchgear standard DIN EN 61439 and its European IEC counterpart. Additionally, we are happy to comply with your in-house standards or, if the system is intended for export, with applicable international standards.
Our Quality Standard: Zero-Defect Tolerance
The final stage of the control cabinet manufacturing process is particularly important: the test stations. At esmatic, no control cabinet is shipped unless it has undergone 100% testing for functionality. Each wire connection, every installed component, and all electrical values are checked using DIN-compliant measurements according to specified criteria. All results are documented in test reports in accordance with DIN EN 61439 (or the corresponding IEC standard). If esmatic developed the automation software, our specialists install it on a trial basis and run a test.
Thanks to partial automation: Efficient Mass Production Guaranteed
esmatic increasingly relies on automated processes for its core mechanical manufacturing operations. This includes state-of-the-art equipment such as the PWA 5000 wiring assistant, which significantly reduces production time and has a positive effect on pricing. Another advantage is that: Once created, templates can be reused when ordering additional control cabinets of the same type, ensuring exact reproduction. Automatic data transfer from EPLAN planning software to designated machines for modification is also possible.
Custom Control Cabinet Manufacturing
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Special requests welcome!
esmatic has the resources and expertise to implement every detail of a control cabinet according to your exact specifications. Our service portfolio covers the entire value chain—from consulting and planning to mechanical manufacturing and assembly with custom components.
Ideally positioned for custom solutions!
Custom control cabinets are in high demand for one-of-a-kind machines or when environmental conditions (e.g., hygiene regulations, temperatures, humidity, space requirements) necessitate control cabinets that go beyond standard specifications. At esmatic, we have geared ourselves toward that exact need with flexible manufacturing processes, a high level of planning expertise, and top-notch equipment.
Take advantage of our engineering expertise and consulting and planning services.
The basic production steps for building custom control cabinets are identical to those for series production. Our standardized process is described in detail on the linked page. The main difference in our approach is that fewer automated machines are used to build custom control cabinets, and consultation and planning are significantly more important.
That is why every project begins with completing our proven questionnaire, which has been used in hundreds of projects. We use it to gather a wide range of information, e.g.,
- In which country will the end customer operate the system?
- What are the environmental conditions at the installation site?
- Does the control cabinet need to meet industry-specific requirements or standards?
- Is the area classified as potentially explosive?
- What cable entries are required, and where should they be located (top/bottom)?
- Do the client or end customer prefer materials from a specific manufacturer?
If you do not have your own planning resources, we will begin planning the automation system based on this information: Our experts use EPLAN to create reliable documentation, according to which we then manufacture the control cabinets exactly to your specifications.
Everything at a glance – thanks to custom, realistic panels
A specialty of esmatic is the integration of informative panels – schematic room overviews with integrated LEDs that display a wide range of safety- and operation-related information.
- Is the alarm system activated?
- What is the operating status of the devices to be controlled?
- Are there any windows or doors still open somewhere in the building?
Our layout diagrams are not prefabricated but are developed individually for each control cabinet. They support the work of the security staff, eliminate the need for time-consuming inspection rounds, and, in the event of a malfunction, provide important clues for efficient troubleshooting.
Mass Production
Consistent Quality
esmatic manufactures your control cabinets in two production halls built specifically for this purpose. These halls have a total floor area of 1,900 m². Our semi-automated production process is equipped with state-of-the-art machinery. This enables us to ensure that all cabinets in a series are identical and maintain a consistently high quality standard. At the same time, partial automation speeds up production. Once all components are available, your control cabinets are usually ready for shipment or pickup in a short amount of time.
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Standardized Processes — Compliant with Standards in Every Respect
The switchgear standard DIN EN 61439 forms the basis for organizing all processing steps. Upon request, we can also align with your in-house standards or the standards of the country where the system will be approved and operated. The control cabinets are manufactured using a standardized process, the most important steps of which are outlined below.
Picking
After receiving the planning and project documents, we check which components are available in our well-stocked warehouse and which must be ordered from our purchasing department. Following a visual inspection, components from the warehouse and delivery stocks are assigned to the picking cart designated for the project and made available for production.
Mechanical Manufacturing:
This is where all planned modifications to control cabinet components are carried out. The first step includes cutting openings for cables, fans, panels, and so on; installing cable ducts and mounting rails; and assembling all components. A detailed list of all activities can be found under the Mechanical Manufacturing menu item, and details about our machinery can be found under Equipment.
Electrical Manufacturing
In the electrical manufacturing department, the control cabinet is wired according to the circuit diagram using the previously installed equipment. For series production, we use an automatic cable assembly machine whose magazines can be loaded with eight different types of wire.
Shipping/Dispatch
After receiving final approval from the production and plant managers, the control cabinets are packed and prepared for shipment, and if necessary, made seaworthy or ready for air freight. We also offer a pre-clearance customs service.
Installation/Commissioning
Upon request, esmatic will handle all work required prior to routine operation on your behalf. Detailed information on this can be found under "Installation and Commissioning."