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⚡ Advanced CNC Manufacturing Facility · Bengaluru

Precision Switchgear &
Panel Manufacturing

Precision-engineered design, assembly, busbar fabrication and 100% in-house testing of custom LV/MV switchgear panels, MCC, PCC, and bus ducts — built to IEC 61439 & IS:8623 standards.

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✓ IEC 61439 Type-Tested
✓ Form 4b Compartmentalized
✓ Class I Licensed
✓ IS:8623 Compliant
KES Switchgear Fabrication Plant
CNC
Manufacturing Plant, Bengaluru
Our Manufacturing Base

Engineered with Precision,
Certified for Performance

From our advanced CNC manufacturing facility in Bengaluru, Kumara Engineering Solutions (KES) designs, fabricates, powders coats, wires, and tests custom LV & MV switchgear boards for industries, IT parks, hospitals, and infrastructure projects across Karnataka.

Every switchboard is built using heavy-gauge CRCA sheet steel (14/16 SWG), 9-tank pre-treatment, automated electrostatic powder coating (Siemens Grey RAL 7032), and high-conductivity 99.97% electrolytic copper/aluminium busbars.

Form-1 to Form-4b Design Up to 6300A Capacity 100kA Fault Withstand IP42 to IP66 Protection Tier-1 OEM Switchgear
Engineering Parameters

Standard Technical Ratings

All KES panels are built to strict IEC 61439-1&2 and IS:8623 standards, with short-circuit withstand test verifications. Custom configurations engineered for every project.

Parameter
Specification Standard
System Voltage & Frequency
415V AC, 3-Phase 4-Wire, 50Hz (MV up to 33kV)
Rated Current Capacity
Up to 6300A (Continuous Rating)
Short-Circuit Withstand
50kA / 100kA for 1 Sec (Type-Tested)
Ingress Protection (IP)
IP42, IP52, IP54, IP55, IP65 (Indoor & Outdoor)
Busbar Material & Plating
99.97% Pure Electrolytic Copper (Silver Plated) / Al
Enclosure Sheet & Coating
CRCA 2.0mm / 1.6mm with 7-Tank Powder Coat (RAL 7032)
What We Manufacture

Our Complete Panel Range

25+ precision-engineered switchgear solutions custom-built for power distribution, motor control, and automation.

LV Switchgear Up to 6300A

LV Switchboards & Main LT Panel

Central power distribution panels featuring ACB/MCCB protection, metering, and compartmentalised Form 3b/4b safety barriers.

  • StandardIEC 61439 / IS:8623
  • Fault Level100kA / 1 Sec
  • ExecutionFixed / Draw-out
Motor Control DOL / Star-Delta / VFD

Motor Control Centre (MCC)

Centralised motor control boards with smart motor protection relays, soft starters, and intelligent interlocking for heavy industrial drives.

  • Supply415V, 3-Phase, 50Hz
  • ConstructionFully Compartmental
  • ControlLocal / Remote / SCADA
Power Control Single / Double Front

Power Control Centre (PCC)

Heavy-duty power receiving and distribution units for continuous plant operation with segregated busbar and cable chambers.

  • ProtectionIP52 Indoor / IP65 Outdoor
  • SwitchgearTier-1 OEM Breakers
  • AccessTop & Bottom Entry
Medium Voltage 11kV / 33kV

MV Switchgear & VCB Panels

High-reliability medium voltage panels equipped with Vacuum Circuit Breakers (VCB) or SF6 gas-insulated breakers for substation incomers.

  • Rating11kV & 33kV Systems
  • DutyIndoor & Outdoor
  • StandardIEC 62271-200
Power Quality Automatic APFC

APFC Capacitor Panels

Automatic Power Factor Correction panels with heavy-duty capacitor banks, thyristor switching, and detuned harmonic filter reactors.

  • Target PF0.99 Unity Maintained
  • RelayMicroprocessor Controller
  • BenefitZero Penalty / Max Rebate
Automation PLC & SCADA

PLC & Automation Panels

Custom programmable control boards with Siemens / Schneider / ABB PLCs, HMIs, and remote telemetry for process automation and BMS.

  • ProtocolModbus / Profinet / BACnet
  • HMI Screen7" to 15" Touch Panels
  • TelemetryCloud / SCADA Ready
Backup Power Auto Sync

DG Synchronization & ATS Panel

Multi-generator automatic load sharing, auto-synchronizing, and Automatic Transfer Switch (ATS) for uninterrupted critical power continuity.

  • Transfer< 8 Sec Auto Transition
  • ControlDeep Sea / ComAp Logic
  • Mains SyncPeak Lopping & Base Load
Transmission 630A to 6300A

HV & LV Sandwich Bus Ducts

Compact sandwich bus trunking systems carrying high continuous currents from transformers to main switchboards with minimal voltage drop.

  • Conductor99.97% Electrolytic Copper
  • ProtectionIP54 to IP66 Certified
  • Fire RatingAS1530.4 Certified
Substation Compact Package

Compact Substation (CSS / USS)

Prefabricated all-weather packaged substations housing 11kV RMU, oil/dry transformer, and LV distribution panel in a single compact footprint.

  • CapacityUp to 2500 kVA
  • StandardIEC 62271-202
  • BenefitRapid Site Deployment
Quality Lifecycle

6-Stage Manufacturing Process

Every panel is built through a disciplined, trackable workflow ensuring zero errors upon site delivery.

01

SLD Review & Costing

Thorough electrical requirement analysis, BOQ estimation, and commercial acknowledgement.

02

GA & Schematic CAD

Complete General Arrangement (GA) drawings and power schematics for client engineering sign-off.

03

OEM Sourcing

Procurement of Tier-1 switchgear (ABB, Schneider, L&T, Siemens) with incoming FAT checks.

04

CNC Fabrication

Precision CRCA cutting, 9-tank pre-treatment, powder coating (RAL 7032) & copper busbar forming.

05

100% FAT Testing

Point-to-point wiring tests, HV insulation dielectric checks, and full functional relay simulations.

06

Site Handover

Protective packaging, on-site positioning, CEIG trial runs, test certificates, and warranty handover.

Calibrated Testing Lab

In-House Quality Inspection Tools

All panels undergo rigorous factory acceptance testing (FAT) using certified, NABL-calibrated testing instruments before dispatch.

HV Dielectric Test

High voltage dielectric strength testing up to 5kV per IEC 61439 standards.

1000V / 500V Megger

Insulation resistance verification across phase-to-phase and phase-to-earth circuits.

Earth Resistance Test

Dedicated Earth Testers ensuring body grounding integrity < 1.0 Ohm.

Secondary Current Injection

Protection relay tripping timing and breaker secondary current injection verification.

Torque & Conductivity

Calibrated torque wrenches on all busbar joints and micro-ohm conductivity checks.

Phase Sequence & Tong Tester

Digital Multimeters, Tong Testers, and phase sequence meters for 3-phase balancing.

Paint Thickness & Gloss

Magnetic dry film thickness (DFT) gauges and scratch adhesion verification.

Temperature Rise Rig

Calibrated current injection test facility for thermal verification up to 4000A.

🛠️ In-House Machinery & Tooling Fleet:
Hydraulic Crimping Presses Hydraulic Busbar Bending Groove & Tile Cutters Cable Drum Lifting Jacks Lux Meters LED Line Marking MIG/ARC Welding Machines
Quality Benchmarks

Our Certifications & Standards

Class I Licensed

Govt. licensed electrical contracting and engineering firm authorized for LT & HT power installations.

Type-Tested Quality

Verified short-circuit withstand up to 100kA, high dielectric insulation, and thermal rise containment.

IEC 61439-1 & 2

Full compliance with international standards for low-voltage power switchgear and control gear assemblies.

IS:8623 & CEIG Ready

Indian Standard compliance and CEIG-ready documentation for statutory government electrical approvals.

Sectors We Supply

Industries We Manufacture For

Our switchboards power mission-critical infrastructure across diverse industries in Karnataka.

Pharma & Biotech
IT Parks & Data Centers
Automobile & CNC
Hospitals & Healthcare
Commercial Complexes
Food & Beverage
Textile & Garments
Chemical & Process
High-Rise Residential
Hotels & Hospitality
Educational Campuses
Cold Chain & Storage

Need a Custom Switchgear Quote?

Send us your Single Line Diagram (SLD) or panel schedule. Our engineering team will review your specifications and provide a comprehensive BOQ submittal within 2 working days.

Request a Technical Quote → Call: +91 99006 04365