How National Manufacturers Reduce Downtime and Cost with Custom Switchgear

At Enercon, we’ve delivered custom switchgear solutions across the full spectrum of industry, both in North America and worldwide. Through ongoing communication with our customers, we’ve gained clear insight into the many benefits that come with moving to custom switchgear—whether as part of a new build or a retrofit project.

Here, we’ll focus on one sector in particular—manufacturing—and take a closer look at the challenges firms face and how custom switchgear can provide the solutions they need to support growth.

The Need for Custom Switchgear

Many firms, including some of the nation’s leading manufacturers, come to us because their electrical infrastructure is outdated and preventing them from getting the most out of their production assets. Older switchgear—often not built for purpose or designed with upgrades in mind—ultimately costs companies money. Here’s why:

Equipment downtime: Aging or outdated switchgear creates more downtime, whether from unplanned outages or routine maintenance. Downtime is costly: expensive equipment sits idle, and personnel trained to operate it often need to be reassigned to other short-term tasks.

Inefficient energy usage: Modern custom switchgear can integrate sensors and remote reporting tools to track energy consumption. This data improves decision-making not only around maintenance but also energy costs and potential efficiencies.

Maintenance costs: Many firms have noted how older switchgear increased maintenance demands, often forcing teams to shift from scheduled work to unplanned repairs. This creates ripple effects across facilities and raises costs, especially through out-of-hours callouts.

Inability to upgrade: Older switchgear not designed with future expansion in mind can create “dead zones” of space—taking up valuable room without leaving capacity for new technologies that could improve efficiency and workflows.

Time and again, our experience in the manufacturing sector has shown that outdated switchgear is not just a source of downtime and risk—it also prevents companies from upgrading their systems and maximizing their assets.

Designing the Right Custom Switchgear Solution

When retrofitting or equipping a new facility, custom switchgear delivers clear advantages over legacy equipment and off-the-shelf solutions. With custom-built switchgear designed around your specific needs, you can expect:

Optimal space utilization: Required floor space can be minimized by combining controls and switchgear, ensuring your power system uses space efficiently.

Regulatory compliance: At Enercon, all of our custom switchgear is built to UL 1558 and UL 891 standards and is NEC 702.12(C) compliant.

Streamlined site interconnects: Installation is simplified by integrating control and switchgear into a unified solution, reducing the need for complex interconnections.

Custom specifications: Whether low or medium voltage, open or metal-enclosed, we build to your exact specifications. This ensures you get the right system for your needs without being saddled with over-specced off-the-shelf equipment.

Positive Results of Custom Switchgear Solutions

For the companies we’ve partnered with, benefits appear immediately and grow over time—especially on their balance sheets. The returns include:

Reduced downtime: Increased uptime of your production assets translates directly into higher returns and improved reliability for your own clients. It also reduces wasted labor hours caused by sudden equipment shifts.

Cost savings: Integrating controls and switchgear lowers costs while maintaining quality. At the same time, predictable maintenance scheduling reduces expenses tied to emergency repairs and after-hours work.

Improved production capacity: A scalable, future-focused electrical system lets you leverage new technologies such as sensors and remote monitoring while also ensuring you can grow and adapt your system as equipment needs evolve.

Enhanced safety: Modern switchgear is built with worker safety in mind. By incorporating advanced arc-flash mitigation, clear labeling, and intuitive layouts, custom solutions help reduce the risk of accidents, keeping personnel safe and minimizing liability for the business.

Sustainability gains: Many manufacturers today are under pressure to reduce their carbon footprint. Custom switchgear makes it easier to monitor energy consumption and identify areas where usage can be optimized, directly supporting ESG goals and compliance with environmental standards.

Future-proofing: Unlike rigid off-the-shelf units, custom switchgear is designed with expansion in mind. As production facilities adopt new automation technologies, renewable energy inputs, or increased load requirements, custom switchgear can adapt without forcing a complete overhaul of the electrical system.

Why Customization Matters in Manufacturing

The manufacturing sector is constantly evolving. Global supply chains, rapid technological change, and the rising demand for efficiency mean that facilities cannot afford electrical systems that limit their growth. Off-the-shelf solutions may look cost-effective at first, but they rarely account for the unique conditions and layout of a specific facility. That’s where customization proves its long-term value.

For example, a manufacturer producing high-value components under tight deadlines needs absolute reliability. A single unexpected outage could not only impact delivery schedules but also strain client relationships. In another case, a facility expanding into more automated production may require highly specialized interconnections that generic switchgear simply can’t accommodate. Custom solutions bridge these gaps by ensuring the electrical backbone is aligned with the company’s specific operational goals.

Conclusion

At Enercon, we bring extensive experience working with companies across industries, including some of the nation’s largest manufacturers. We’ve seen firsthand how custom switchgear can deliver measurable benefits—reducing downtime, minimizing space requirements, streamlining maintenance, and boosting production capacity with smart monitoring technologies.

For today’s manufacturers, the question is not whether they can afford to invest in custom switchgear—it’s whether they can afford not to. With operational efficiency, energy costs, safety, and long-term scalability all on the line, the returns speak for themselves.

To learn how Enercon can help your company reduce downtime, cut costs, and future-proof your systems, connect with us today about your next project.