Manufacturing and distribution sectors are now embracing automated systems more than ever. Automation increases productivity, enhances quality control and significantly reduces operational costs. However, if these systems develop faults or break down, your business is at risk fiscally, with the brand being damaged. More importantly, employees’ safety will be put at risk.
So how do you ensure your automated systems work reliably and efficiently? Carrying out regular electrical inspections and testing on all equipment is vital to maintain a safe working environment, comply with regulations, and ensure your systems run at peak efficiency.
With the peak season for both manufacturing and distribution around the corner, testing your automated system, be it conveyor systems, process lines or your old reliable control panel, is vital. Downtime in the final quarter of the year can be detrimental—not only financially, but also to your brand’s credibility and reputation.
To ensure you are not caught out, let’s explore the 5 main benefits of regular electrical testing for automated systems.
1: Improved System Safety
Even the smallest issues, like frayed wiring or damaged insulation, can electrocute employees, resulting in severe injury, burns, spasms and even cardiac arrest. The worst cases can leave people with life-changing physical, psychological and neurological impairments. That’s why regular, thorough testing of your electrical systems, carried out by a trusted partner, is essential to keep your employees, contractors and visitors safe.
A detailed visual inspection serves to identify faults and wear and tear. For instance, frayed or faulty wiring could overheat, leading to an electrical fire.
Additionally, instrument testing on voltage, current, insulation and checks to detect a lack of grounding are crucial to discover faults and ensure equipment works efficiently. Our Engineers can support with: Thermographic inspections, Loop impedance testing, Residual current device (RCD) testing and Harmonic distortion analysis in facilities with high-speed motors or VFDs. These early detections of minor faults can prevent catastrophic failures, costly downtime, and serious safety incidents.
2: Decreased Downtime
Electrical faults are a major cause of unnecessary and costly downtime for manufacturing and distribution businesses. According to Hazardex, Food manufacturers experience 442 hours of equipment downtime per year — more than 8 hours per week. This unplanned downtime led to a projected cost of £4-5 billion for 2025.
Regular electrical testing can reduce the likelihood of downtime in the long term. Detecting problems early can prevent unexpected issues that may cause a system failure and production stoppages. By maintaining more reliable systems and equipment, you can boost productivity and enhance efficiency across your business.
3: Cost Savings
Regular automation maintenance will keep your operation cost-effective. It will:
- Extend the lifespan of your equipment
- Prevent costly emergency repairs
- Remove the need to replace equipment prematurely
- Reduce materials wastage (essential for food processing facilities)
- Lower insurance costs through creating a safer work environment
- Lower energy bills by maintaining system efficiency.
4: Meets Industry and Legal Requirements
Your business must comply with key electrical safety regulations—including the IET Wiring Regulations (BS 7671), Electrical Installation Condition Reports (EICR), and the Health and Safety at Work Act.
These certifications aren’t just legal obligations—they’re strategic tools that can enhance operational efficiency. Regular electrical inspections provide detailed reports that support audits, streamline insurance claims, and reduce liability risks. By proactively identifying faults and inefficiencies, you can prevent costly downtime, improve safety, and strengthen your brand’s reputation.
5: Increased Efficiency and Performance
Regular electrical inspections are critical to maintain productivity and quality control in an automated system.
An experienced electrical engineer can identify issues that may be slowing your system down and fix them promptly, helping to increase efficiency and performance.
How Often Should You Inspect and Test an Automated System?
The number of electrical inspections required depends on multiple factors, including:
- Your business’s relevant industry and legal regulations
- How much use the system gets
- The age of the system.
Industry is also a factor. Electrical systems in hazardous environments with potentially explosive elements, such as gases and vapours, require monthly or quarterly checks to ensure safety.
Electrical Test and Inspection Services at Elmleigh
Regular electrical testing and inspections not only enhance the productivity of your automated systems but are essential to ensuring a safe work environment.
Elmleigh’s experienced and trusted electricians are proud to provide high-quality testing and inspection services to ensure your systems operate safely, reliably and comply with the relevant legislation for your business. Additionally, our ATEX-approved electricians can inspect and test electrical systems in hazardous areas.
Contact us today on 01455 847045, or fill out the form on our contact page for a comprehensive electrical testing and inspection service.