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Control Panel Manufacturing

Custom control panel design & fabrication

Process Solutions provides custom UL control panel design and fabrication services for almost any industry or application. We work closely with our clients to understand their requirements and deliver tailored solutions to improve process control and maximize productivity.

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Assured Compliance

UL certified panel shop

UL 508A Panel Shop

Process Solutions is a UL certified control panel shop specializing in the design and build of UL 508A custom control panels. Our expertise also extends to UL 698A, 1203, and 1604 control panels designated for hazardous locations.

Process Solutions is recognized as an industry leader in quality and expertise, holding certificates as a Rockwell Automation Partner, Siemens Solution Partner, and AVEVA Certified Systems Integrator.

WORK EXAMPLES

WORK EXAMPLES

Panel Example 5
Panel Example 3
Panel Example 1
Panel Example 6
Stacklight Panel Example
Drive Panel Example
Control Panel Example
Custom PLC Control Panel Built by Process Solutions
Custom Control Panel with Servo Drives Installed
Industrial Control Panel With and IO rack and Stainless Steel Enclosure
VFD control panel with yellow terminal wiring
Panel Example 4
GE PLC Panel
Electrical Control Panel in Stainless Steel Enclosure
VFD Panel Example 2
Stainless Steel PLC Panel Example
Two-door VFD Control Panel in stainless steel enclosure
Two Door Panel Example
VFD Control Panel in a Stainless Steel Enclosure
Three Door VFD control panel with remote I/O and a disconnect switch
Sloped Enclosure Example
PLC Example Two
HMI Enclosure Interior Example

Control Panel Manufacturing Services

Setting the standard for industrial control panel quality and performance

Control panel design

Our control panel design services entail a thorough evaluation of your specifications to ensure we meet your exact requirements. We account for every detail, including the install environment, heat calculations, electrical requirements, sizing, and any existing controls equipment.

When selecting components, we only incorporate those from leading suppliers with proven reliability over thousands of installations, including Allen-Bradley, Siemens and more.

Before being released to production, the panel is modeled in AutoCAD and reviewed by senior-level engineers to ensure quality and regulatory compliance.

Engineering services

With hundreds of combined years of control systems integration experience, our hardware and software engineers provide a range of services, including electrical and mechanical design, PLC and HMI programming, documentation, on-site or remote commissioning, and post-project support.

Our documentation packages include panel layout drawings, wiring schematics, functional diagrams, O&M manuals, I/O lists, software design documents, and FDA level drawings.

Control panel build

Our skilled technicians build over 3,000 custom control panels per year out of our 60,000 sq. ft. manufacturing space. Our specialized tooling, including our pair of automated milling machines, automated lamacoid engraver, tilting work benches, and dedicated wiring stations, streamline production and help ensure our exceptional build quality.

To ensure clean and organized panel wiring, we equip properly sized wire duct and adhere all device and wire labels in easy to read locations.

Before delivery, every control panel undergoes a thorough quality inspection and is tested for complete functionality.
Solutions for Industry

OEM, build-to-print and serial production

Building custom or pre-designed control panels for OEMs is a particular specialty. Our build-to-print control panel services include engineer-led design reviews to ensure compliance of pre-existing control panel designs with industry standards and to offer recommendations for cost savings and manufacturing efficiency. We also provide parts procurement, control panel manufacturing, documentation, factory acceptance testing, and commissioning services.
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Custom Cutouts & Machining

Precision milling services

Our pair of automated enclosure and panel mills provides quick, clean and precise cutouts of any shape or size for mounting controls interfaces, components, and wireway. Cutouts can be made in mild or stainless steel, plastic, and fiberglass. There are no minimum order requirements and our mills can accommodate enclosure dimensions up to 88″ x 88″ x 94″. Quick lead times available for custom enclosure and panel milling projects.

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Panel Example 1
Drive Panel Example
Stacklight Panel Example
Panel Example 7
Panel Example 6
Panel Example 5
Panel Example 3
Panel Example 4
Panel Example 2
GE PLC Panel
VFD Panel Example 2
HMI Enclosure Interior Example
PLC Example Two
PLC Panel 2-door Example
Sloped Enclosure Example
Stainless Steel PLC Panel Example
Three Door VFD control panel with remote I/O and a disconnect switch
Two Door Panel Example
Two-door VFD Control Panel in stainless steel enclosure
Custom Control Panel with Servo Drives Installed
Custom PLC Control Panel Built by Process Solutions
Industrial Control Panel With and IO rack and Stainless Steel Enclosure
Custom Control Panel Builder
Electrical Control Panel in Stainless Steel Enclosure
VFD control panel with yellow terminal wiring
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Vaclav Mydlil
Sr. Director of Advanced Automation
Vaclav leads the dynamic Energy Management and Refrigeration Division at Process Solutions. With an impressive 20 years of experience in power demand management and refrigeration control systems, Vaclav is the driving force behind one of the company’s most innovative systems.

His expertise extends to PLC and cloud-based systems, ensuring seamless integration and optimal performance. Vaclav’s commitment to excellence is underscored by his Master of Science degree, specializing in control systems and electrical engineering, which he earned from the University of Life Sciences in Prague, Czech Republic.

Beyond the office, Vaclav’s passions include kayaking, snow skiing, and woodworking. Most of all, he enjoys moments spent with his wife and three kids.
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Steve Pelton
Vice President of Sales
With over 20 years at Process Solutions, Steve Pelton has held various roles, including Sales Engineer, Sales Director, and his current position as Vice President of Sales.

In addition, Steve oversees Process Solutions’ Energy Management and Refrigeration Division — ensuring the company remains at the forefront of energy-efficient solutions that cater to diverse food production applications. Steve also spearheads the strategic development of the company’s machine monitoring solutions, aligning them with client needs and market trends.

Steve’s background includes mechanical engineering, but his career trajectory has mainly focused on control systems marketing and management. His ability to bridge technical expertise with business acumen has been instrumental in Process Solutions’ growth.

Outside the office, Steve passions include conquering rugged trails on his mountain bike, perfecting his golf swing, and exploring new destinations with his family.
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Matt Barnes
Chief Financial Officer
Matt, with 28 years of financial strategy and accounting experience, plays a pivotal role at Process Solutions. As the Chief Financial Officer (CFO), he spearheads the company’s growth strategy, ensuring financial stability and health.

Beyond traditional financial management, Matt also oversees strategic initiatives aimed at optimizing Process Solutions’ on-hand inventory costs and availability. By fine-tuning inventory management, Matt ensures the company can meet client needs efficiently and maintain a healthy bottom line.

Matt graduated with a degree in accounting from Western Washington University and previously served as a financial executive at a large retail corporation. Outside of work, Matt enjoys traveling, soccer and spending time with his family.
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Kevin Orr
Executive Vice President
Kevin boasts an impressive tenure of over 25 years at Process Solutions. His position in the company has been multifaceted, spanning roles as a project engineer, engineering manager, and Process Solutions’ first Executive Vice President.

Under Kevin’s leadership, the food processing division has flourished, earning its reputation as of the most respected in the industry. Today, Kevin closely collaborates with executives from leading food processors and food processing equipment manufacturers across the country.

Kevin is a devoted husband and father with a passion for international travel.
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Todd Busby
Chief Executive Officer
Todd has dedicated over 30 years to Process Solutions, where he has worn multiple hats—from panel builder to project engineer and sales representative.

As the CEO of Process Solutions, Todd has spearheaded significant transformations. Under his leadership, the company has diversified into new industries, acquired a world-class facility, and more than doubled its size.

Todd, a native of the Puget Sound region, is a devoted husband, father, and avid outdoorsman. When he’s not at work, you’ll find him supporting his three kids in all their pursuits or hunting and fishing in Eastern Washington.
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David Crumpley
President
David has dedicated over 15 years to Process Solutions, where he has served as a Senior Engineer, Vice President, and now Chief Operating Officer. His multifaceted experience spans technical expertise, strategic leadership, and operational efficiency.

As the head of Process Solutions’ Water/Wastewater division, David orchestrated the modernization of the company’s internal systems and boosted operational efficiency across the organization.

In his current role as President, David continues to drive innovative initiatives aimed at expanding the company’s reach and further streamlining internal processes.

Outside of work, David enjoys spending quality time with his family and pursuing his passions as an avid outdoorsman.
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Services

Service

We provide numerous remote and on-site services to our customers, including software upgrades, troubleshooting, hardware replacement, and feature additions. Our staff size provides us flexibility to quickly respond to standard time frames and emergency service.
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Services

Commission

Process Solutions provides commissioning services, as well as system start-ups. Our staff will travel anywhere in the world to help you get your system up and running. We start up hundreds of systems per year, and our licensed electricians on staff can pull permits as needed.
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Services

Document

Our Engineering and CAD department can create a wide range of documents, including functional specifications, software design documents, test manuals, O&M manuals, P&ID, system drawings, and network drawings. Drawings for FDA level documents are a particular specialty.
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Services

Code

Process Solutions software designers are equipped to handle any size job. We structure our program code to be easily read by both customers and engineers, making support and system upgrades fast and easy.
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Services

Build

Process Solutions builds over 3,000 panels per year. Our high-volume model makes our technicians experts in the field and provides our customers with an industry leading experience. Efficient manufacturing practices, mixed with automated manufacturing equipment, allows for quick and consistent job completion.
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Services

Design

Creation of custom designs for new and legacy systems. All drawings are template based using automatic CAD macros. Our techniques create an efficient design process with recognizable and easy to understand drawings.
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