Custom Pneumatic Control Panel Replacement for a Key Industrial Site

Case Study Overview

‍

Sector: industrial materials processing

‍

Challenge: an ageing and unreliable pneumatic panel was causing unplanned plant downtime and operational inefficiencies.

‍

Solution: a custom pneumatic control panel replacement designed, built and tested by Camozzi Automation UK.

‍

Products / technology used: bespoke pneumatic control panel, 2D/3D CAD design, pneumatic components and enhanced panel protection.

‍

Result: a plug and play replacement panel delivered within four weeks, supporting improved reliability, easier maintenance and longer service life.

‍

Discuss a Control Panel Requirement

‍

‍

Situation: Ageing Pneumatic Panel Causing Unplanned Downtime

‍

A materials processing facility specialising in aggregates, concrete and recycled building materials required support to replace an ageing and unreliable pneumatic control panel.

‍

The existing solution had started to fail, leading to unplanned plant downtime and operational inefficiencies.

‍

Having previously supported the site with a solution that had proven robust and suitable for the working environment, Camozzi Automation UK and HAYLEY DEXIS | Fluid Power were approached again to assist with the latest issue.

‍

‍

Challenge: Replacing the Existing Panel Quickly and Reliably

‍

A Camozzi representative and customer representative visited the site to assess the application and ensure a seamless replacement of the existing control panel.

‍

The goal was to replace the incumbent pneumatic panel as quickly as possible, while maintaining operational efficiency and improving system protection and durability in the facility’s demanding environment.

‍

By engaging directly with the customer to understand their requirements and preferences, the team specified a complete plug and play pneumatic control panel replacement that could be installed with minimal disruption.

‍

‍

Solution: Custom UK Panel Design, Build and Testing

‍

Within 24 hours, a detailed quote was provided.

‍

Once approved, the Camozzi Automation UK technical team developed CAD drawings based on the existing panel layout. The design was created to support straightforward installation and easier future maintenance.

‍

From concept to completion, including design, build and testing, the full custom pneumatic control panel project was delivered within four weeks from order placement.

‍

The new Camozzi control panel was produced with enhanced ingress protection, helping improve durability for the instrumentation and electrical components in the facility’s demanding environment.

‍

This gave the customer a more robust replacement solution designed to support longer service life and reduce the risk of future downtime linked to valve failures or electrical faults.

‍

‍

Result: Improved Reliability and Easier Maintenance

‍

A fast turnaround was key to minimising plant downtime and helping the customer resume operations without delay.

‍

The new control panel resolved the existing reliability issues while improving protection, durability and maintainability on site.

‍

With its robust construction and enhanced protection, the pneumatic control panel upgrade simplified future maintenance and supported longer term operational reliability.

‍

The customer’s decision to work with Camozzi Automation UK and HAYLEY DEXIS | Fluid Power for a second installation reflects the reliability of the previous solution and the value of the ongoing technical partnership.

‍

‍

Why Camozzi Automation UK?

‍

This project highlights Camozzi Automation UK’s ability to support customers with practical application engineering, bespoke panel design and UK based build capability.

‍

By combining technical assessment, CAD design, panel assembly and close distributor collaboration, Camozzi helped deliver a replacement solution suited to the customer’s site conditions and operational needs.

‍

For industrial sites dealing with ageing pneumatic panels, reliability issues or difficult maintenance access, Camozzi Automation UK can help review the application and discuss a suitable control panel replacement route.

‍