40 n ELECTRICAL AND ENCLOSURES November/December 2025 www.drivesncontrols.com The critical role of cooling in avoiding production disruptions UK manufacturers are currently trying to navigate a long list of economic and logistical challenges, from supply chain issues, to skills shortages and high energy costs. In response, many are focusing on improving the performance of existing assets, while protecting margins by streamlining processes to avoid downtime, and keep lines running smoothly. However, equipment breakdowns are still happening on an almost epidemic scale. According to recent research by IDS-Indata into the true cost of manufacturing downtime, more than 80% of industrial businesses in the UK and Europe experienced unplanned downtime in the past three years, with each incident lasting around four hours. While many things can lead to equipment malfunctions, the research indicated that software and systems failures are leading causes of downtime. This is backed by evidence that we, at Rittal, have gathered from site visits and equipment surveys. Our data suggests that inadequate dissipation of heat around electrical components has become a major problem and is likely to be the root cause of many failures. For example, the reliability and performance of devices such as PLCs, VSDs and transformers – which are indispensable for production line processes and maintaining seamless operations – can be affected by poor climate control. All three are highly sensitive to temperature variations, which is almost certainly why we are seeing a correlation between the recent trends in manufacturing downtime and challenges associated with maintaining optimal operating temperatures. Overheating can lead to costly breakdowns, production delays, and even permanent damage to vital equipment. The issue is becoming more common as technology advances and as more businesses invest in sophisticated electrical systems, including AI, to support their operations. Meanwhile, essential maintenance may be being deferred, which will only amplify the risk of cooling-related equipment failures. Furthermore, existing cooling infrastructures may be struggling because of higher operational demands, particularly if systems or circumstances have changed since the equipment was installed. We’ve seen an increased frequency and intensity of summer heatwaves in the UK in recent years, leading to a rise in ambient temperatures, which is adding to the demands on industrial cooling systems. Why are they vulnerable? PLCs incorporate sensitive electronic components. Exposing these components to higher-than-optimal temperatures means that they can degrade, which can cause intermittent operational errors, impaired performance and, eventually, can result in complete system failures. Similarly, VSDs that regulate electric motor speeds generate substantial levels of heat during operation. Insufficient cooling – or airways that have been blocked by dust and debris – can mean that their internal components overheat, resulting in shortcircuits and drive malfunctions. Even transformers, which are vital for electrical power distribution, are susceptible to thermal stresses that may compromise their insulation, potentially initiating catastrophic failures. Manufacturers can put procedures in place to help mitigate the damaging effects of overheating. These include: Manufacturers are grappling with challenging trading conditions which are putting pressure on their margins. Many are placing a greater emphasis on improving operational efficiency. However, unplanned downtime caused by production line failures is still alarmingly common. As Rittal’s service manager, Andy McPhee, explains, overheating is often at the root of these failures. Effective cooling can be essential if you want to keep your equipment running reliably, especially in challenging environments
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