Why is it so hard to get a straight answer on automation costs?
Industrial automation is not like buying a piece of equipment with a price tag. Every project is different.
Scope, existing infrastructure, control platform, and support level all affect the final number significantly.
That said, after two decades of delivering automation projects across UK manufacturing, marine, and process industries, we can give you realistic budget ranges to sanity-check quotes and plan capex accurately.
PLC Control Panel: Budget Ranges
A standalone PLC control panel is often the starting point. Costs vary based on I/O count, enclosure specification, panel rating (IP54, IP65, ATEX), and the control platform chosen.
| Panel Type | I/O Count | Typical Cost (Supply + Install) |
|---|---|---|
| Small machine control panel | 16–64 I/O | £8,000 – £25,000 |
| Medium production line panel | 64–256 I/O | £25,000 – £80,000 |
| Large process control panel | 256–1,000+ I/O | £80,000 – £300,000+ |
SCADA System: Budget Ranges
SCADA costs include software licences, server hardware, engineering (screen development, tag configuration, alarm rationalisation), and commissioning. Open-source platforms like Ignition reduce licence cost significantly.
| System Size | Tag Count | Typical Cost |
|---|---|---|
| Small SCADA | Up to 500 tags | £15,000 – £60,000 |
| Medium SCADA | 500 – 5,000 tags | £60,000 – £250,000 |
| Enterprise SCADA | 5,000+ tags | £250,000+ |
Systems Integration: What Drives the Cost
Connecting legacy PLCs, drives, and instruments to a new control system is where most projects overrun their budget.
The main cost drivers are:
- Protocol compatibility — older equipment may need protocol converters or gateway hardware
- Cable and trunking works — often underestimated in brownfield sites
- FAT and SAT testing — factory and site acceptance testing adds 10–20% to engineering hours
- Production downtime — cutover during planned shutdowns adds planning cost but saves lost production
Annual Support and Maintenance Costs
Ongoing costs are frequently overlooked in capex planning. Make sure you budget for:
- Software licence renewal: typically 15–20% of initial licence cost per year
- Annual preventive maintenance visit: £2,000 – £8,000 depending on system complexity
- Remote support contract: £3,000 – £12,000 per year for priority response
- Spare parts holding: budget 5–10% of hardware value for critical spares
How to Get an Accurate Quote
The more detail you provide, the more accurate your quote will be. Gather this before approaching an integrator:
- A list of equipment to be controlled (motors, valves, instruments) with quantities
- Existing control platform (if any) and whether it stays or is replaced
- Process description — what the system needs to do, not just what equipment is present
- Any regulatory, ATEX, or SIL requirements
- Your preferred planned downtime window for cutover
Request a detailed project estimate from Ashmit Engineering →
