+44 121 753 0077Heater control panels
Custom-designed and built in the UK to provide accurate, reliable temperature control for surface heating elements, flexible heated hoses, and industrial thermal process systems. Engineered for precise thermal management, maximum energy efficiency, and total operational safety.
Custom Temperature Control Panels
Accurate temperature control is essential for maintaining product consistency, preventing material degradation, and protecting heating equipment from thermal overload. We design and manufacture bespoke heater control panels tailored to your exact operational requirements and site electrical parameters.
Using state-of-the-art electronic digital controllers from industry-leading manufacturers, our panels ensure your process achieves and holds target temperatures with minimal thermal overshoot. By supplying only the precise amount of thermal energy required by your application, our control systems optimize heating performance while actively reducing energy consumption and operating costs. From compact single-zone enclosures to complex multi-zone panel builds, every unit is assembled to meet your environmental conditions—including high-IP weatherproofing for outdoor or wash-down areas, and intrinsic safety protection where hazardous area standards are required
Technical Specifications
- Precision Thermal Control: Outfitted with advanced PID controllers for steady thermal regulation across heating elements, jackets, and transfer hoses.
- Environmental Sealing: Available with enclosure ratings up to IP65 / IP66 for complete protection against dust, water jets, and harsh outdoor elements.
- Intrinsic Safety Options: Engineered with intrinsically safe barriers and ATEX-compliant components for hazardous area applications.
- Energy-Efficient Switching: Incorporates Solid State Relays (SSRs) or contactors to minimize power draw and deliver exact heat cycles.
- Universal Voltage Support: Manufactured to suit all standard UK, European, and international site voltages (110V, 230V, and 400V 3-phase).
- Bespoke Build Options: Tailored enclosure sizes, custom mounting layouts, and auxiliary wiring connections integrated directly into the panel build.
Engineered Process & System Integration
Off-the-shelf temperature controllers rarely fit the exact operational demands of complex industrial sites. Whether you are running surface heating jackets on process vessels, maintaining fluid viscosity across long heated hose runs, or retrofitting legacy equipment, your control system must deliver consistent thermal stability without nuisance tripping or operator guesswork.
Every panel we build is designed for straightforward site installation and seamless integration into your current workflow. We balance power switching, sensor feedback loops, and safety isolation within a clean, logical internal layout.
- Preventing Thermal overshoot: Precision PID tuning prevents temperature spikes that can degrade sensitive process fluids, burn out heating elements, or damage hose linings.
- Seamless Auxiliary Connectivity: Need your heater to switch off automatically if a pump stops or a process valve closes? We can integrate auxiliary interlocks, remote enable inputs, and signal feedback loops to connect your panel directly to your central PLC or main machine automation.
- Built for Operator Safety: Dedicated over-temperature safety cutouts operate on independent sensor circuits, ensuring immediate power shutdown in the event of a system fault or thermal runaway condition.
For any enquiries, call us on +44 121 753 0077 or email sales@flexibleheatedhoses.com
| Feature | Technical Specification & Build Options |
|---|---|
| Dimensions & Layout | Manufactured to required custom dimensions and mounting layouts to suit your space. |
| Enclosure Types | Powder-coated mild steel, stainless steel (304 / 316), or heavy-duty weatherproof enclosures. |
| Protection Ratings | Standard IP-rated builds up to IP65 / IP66; intrinsic safety / ATEX options where required. |
| Control Capacity | Configured for single-zone or multi-zone surface heater and hose management. |
| Temperature Sensors | Fully compatible with PT100 (RTD), Type J, Type K thermocouples, and mechanical thermostats. |
| Switching & Control | Equipped with Solid State Relays (SSRs), mechanical contactors, or thyristor power controllers. |
| Display & Interface | Digital LED displays, programmable PID controllers, touchscreen HMIs, or simple analogue dials. |
| Safety Systems | Integrated over-temperature cutouts, circuit breakers, fuses, and emergency stop circuits. |
| Voltage & Power | Built to match your electrical supply: 110V site transformers, 230V single-phase, or 400V 3-phase. |
| Auxiliary Options | Additional control wiring, sensor loops, or pneumatic tubes incorporated directly into the build. |
Can your control panels handle multi-zone heating setups?
Yes. We regularly design and build multi-zone control panels where different sections of a heated hose line, vessel jacket, or surface heater surface require independent temperature monitoring and separate control loops.
Can additional control wires or pneumatic lines be integrated into the panel build?
Absolutely. We can incorporate extra auxiliary wiring, signal pass-throughs, or supplementary tubes directly into the control panel build to operate external machinery, feed automated signals back to a main PLC, or power auxiliary site equipment.
Do you supply panels suitable for outdoor or wash-down environments?
Yes. We build enclosures sealed up to IP65 or IP66 standards in both high-grade stainless steel and powder-coated steel, ensuring complete protection against water, moisture, dust, and corrosive wash-down chemicals.
Can your control panels handle multi-zone heating setups?
Yes. We regularly design and build multi-zone control panels where different sections of a heated hose line, vessel jacket, or surface heater surface require independent temperature monitoring and separate control loops.
Can these control panels be integrated into a central PLC or SCADA system?
Yes. We can equip our control panels with digital communication protocols such as Modbus RS485, Profinet, or Ethernet/IP. This allows your central PLC, SCADA system, or plant management software to remotely monitor process temperatures, adjust setpoints, log historical data, and receive immediate fault or alarm notifications.
What safety features are included to prevent thermal runaway?
System safety is paramount. In addition to primary temperature sensors, our control panels can be fitted with independent limit controllers (over-temperature cutouts) wired to secondary sensors. If the primary controller or sensor fails, or if a fluid line runs dry, the independent limit controller mechanically isolates the heating circuit, requiring a manual reset before power can be restored.
Can you supply control panels that accept multiple sensor input types?
Absolutely. Most of our digital controllers feature universal sensor inputs, meaning they can be configured via menu options to accept 2-wire or 3-wire PT100 (RTD) sensors, as well as Type J, Type K, or Type T thermocouples. If you are replacing an old control panel but keeping existing sensors in the field, we can match your wiring parameters seamlessly.
Can your panels be retrofitted to control non-standard or legacy heating equipment?
Yes. Because we build to order in our UK workshop, we routinely engineer replacement panels for legacy plant machinery, foreign-made OEM equipment, or bespoke heating rigs. Provide us with your heater’s wattage ratings, operating voltage, sensor type, and control requirements, and we will design a modern, compliant panel that drops straight into your existing setup.
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In Business for
over 30 years.
In Business for over 30 years.