2011 was a big year for Integra Enclosures. We rolled out one of our most important products yet, the Genesis Line 24x24x10—the largest enclosure of its kind and specs to hit the U.S. market. A product rollout like this is a monumental endeavor, which began more than four years ago. I was recently asked, “what would you have changed or kept the same about the process of guiding this product to market?” In response, here are four thoughts:

• Let your customers be your focus group. We spend a lot of time going and talking to Integra customers where they are and seeing how they’re using enclosures to protect equipment. They were the ones who let us know that a 24x24x10 enclosure was needed in the marketplace, and their insights on the features and specs of this product were directly integrated into the design that we gave the Genesis Line. Even throughout the design phase, we constantly showed the product to customers and tweaked revision upon revision, relying on their feedback to be sure we ended up with the best enclosure. There’s hardly a better focus group than your customer—the people who are using your product day-in and day-out.

• Design engineers are invaluable. Truth told, we began this process largely without the aid of design engineers, but as we dove deeper into the process of making the Genesis Line 24x24x10, we quickly realized how vital their insights are to the process of creating a new product such as this. You might ask, “Weren’t you essentially creating another enclosure, just scaled up from the models you’re already producing?” Yes, we were adding another line, but this endeavor was similar to the challenges a car company faces when implementing a line of trucks. Yes, they’re both vehicles, but cars and trucks demand totally different features, design considerations and manufacturing processes. Design engineers have the expertise to anticipate every need that implementing a new product line will demand.

• Pick a project champion. This leadership lesson is one you’ve heard before. As an organization leader, you need to be free to respond to all aspects of the business. So when launching a new product line, pick a trusted product champion from your team who will own every aspect of the process. At the same time, don’t be afraid to add your own flavor to the product. Be involved in the process enough to add your input and the input you hear from your customers, and let the design engineers have latitude to produce the best product possible.

• Don’t Be Afraid to Step Forward. If there’s one thing we might have done differently in introducing the Genesis 24x24x10, it would have been to do it sooner. As manufacturing leaders, it’s too easy to let other initiatives and products crowd what you know will be an important advance for your company. We knew a long time ago that that the Genesis 24x24x10 would fill a need in big way for our current customers and potential customers. But it took time to launch the project in earnest. In the future, Integra is going to be quicker to launch new product lines in response to what our customers want. Yes, it’s a big endeavor, but it’s the key to pushing forward in a fast-changing market.

Rising cost of steel is one factor that will fuel a move away from stainless steel-made enclosures. In turn, more and more people will demand an alternative to fiberglass enclosures, such as polycarbonate, which doesn’t warp or splinter like fiberglass does (to name just a couple attributes). This shift will mirror what’s already been happening for a while in Europe, where the cost for steel has already risen.

Demand for enclosures will increase in the smart grid industry, to name one. Power companies have begun implementing and refining power distribution at the individual residence level. By placing controls inside an enclosure on the house exterior, utility companies can coordinate when power is served, and the dollar savings as a result are phenomenal. For example, by staggering when different homes’ air conditioning turns on, power companies can drastically reduce the energy draw. This example, while granular, shows just one way that the smart grid is adapting and finding new, creative applications – many of which will require reliable equipment protection solutions. These and other emerging technologies will be the primary driver for the enclosure market, in contrast to the days when the automotive industry and other big players set the course for enclosures.

OEMs will opt to work directly with enclosure manufacturers more than ever. As manufacturers provide the service and lead times OEMs need, more of these companies will choose to deal directly in order to benefit from cost savings.

Polycarbonate enclosures will earn a bigger share of the market in the coming years. As more engineers and industry professionals realize the benefits of the polycarbonate enclosure material—such as strength and durability—the demand for this non-metallic enclosure option will grow.

No question: the industries we serve are changing quickly, and we have to be nimble enough to adapt our enclosures to their applications.  In any case, it’s an exciting time to be in the business of equipment protection. Feel free to share your thoughts and predictions in response!

We’re also rolling out some new accessories this year. For example, a three-point locking latch will be available for our Genesis Line. On this smart lock, one handle works a three-point latch.

In terms of trends in 2012, growth in the solar industry is bringing more and more opportunities as solar businesses are using Integra Enclosures to protect solar control and monitoring equipment. And with our home operations in Mentor, Ohio, any reason to visit our solar customers/friends west of the Mississippi is a great idea (especially in February…) Of course, we’ll continue to serve more customers in some of our core industries like the smart grid and remote monitoring, where the need for rugged equipment protection is vital.

Here at Integra headquarters, we’re preparing for a year of growth, and we’re adding new team members, too. We’re also looking forward to meeting one-on-one with current customers and some new folks at a few trade shows, including WEFTEC and the Offshore Technology Conference (OTC) in Houston. All told, 2012 looks like it will be a great year for Integra. Share with us: What’s on your 2012 horizon?

Integra Enclosures’ own Steve Anderson was featured this month Electronics Protection Magazine. Read his article, “Protection Selection: Guidelines for Choosing Remote Monitoring Enclosures” online!

(And look for another article from Integra President, Jim McWilliams on upcoming changes in UL standards for enclosure manufacturers!)

Marinas
Integra Polycarbonate Enclosures are a smart choice for marinas and other marine applications because they can withstand the extreme temperature conditions of the sea. Whether the frigid winter wind or the burning summer sun, Integra Enclosures have proven to last without warping or damaging the valuable equipment inside. Integra Enclosures carry high NEMA/IP ratings, for protection against moisture and dust, as well as corrosion resistance.

Remote Monitoring
Thanks to their proven strength and reliability and incredible customization, Integra Enclosures can be found in some of the most remote parts of the world, providing protection to important and expensive electronic equipment.

One of the most valuable features of Integra’s polycarbonate enclosures is the lack of radio signal interference. When  radio monitoring equipment is housed inside a metal enclosure, often the radio antennae must be mounted outside the enclosure to avoid interference from the metal enclosure. This can cause security risks, because antennas stored outside of the enclosure can signal to would-be thieves that valuable equipment is stored inside. Since Integra polycarbonate enclosures do not interfere with radio signal, the antenna can be housed inside the enclosure, providing a much more secure solution for housing remote monitoring equipment.

Golf Courses
Integra Enclosures can even be found on golf courses around the world! When appearance matters, Integra has the solution. Integra Enclosures can be fully modified, which includes custom panels and colors, including clear covers. Each enclosure is engineered to last: the Premium Line enclosures have an impact resistance of over 900 lb/in! That’s more than enough to withstand the impact of a stray golf ball (or club)! Other fiberglass enclosures typically have an impact resistance of less than 220 lb/in.

Integra Enclosures are found in a variety of applications across the globe (oh, did we mention that there’s an Integra Enclosure in the Bellagio in Las Vegas?) because of their strength, reliability and customizability.

In my last post, I discussed some types of configurability an enclosure producer should be able to offer in order to get the most protection possible for your electrical equipment. In this post, I’ll briefly cover some of the most important assembly, shipping and manufacturing standards you should make sure your potential enclosure provider adheres to.

UL-Listed: Is the enclosure manufacturer producing products that are UL-Listed? This should be a non-negotiable. When an enclosure is UL-Listed, that means it can safely contain electrical equipment. UL-50 is a standard rating for enclosures that aren’t storing high voltage equipment. Manufacturers who produce UL-Listed products undergo regular inspections to ensure the safety of their products, which ultimately ensures the safety of your products.

Manufacturing In-House: Will your enclosure be manufactured in-house? While this may seem trivial, it is a smart idea to directly know and be in contact with the people who are intimately involved with constructing your product.

Shipping & Assembly: Similarly, how will the enclosure be shipped? Ideally, your enclosure should be shipped already assembled with the base, and the gasket should be pre-installed on the cover.

NEMA Rated: When you’re in the market for an enclosure, you should know the NEMA rating that your application demands. NEMA Standards Publication 250-2003b identifies the specs for enclosures for electrical equipment with a maximum voltage of 1000. Although the environment for your enclosure will dictate your NEMA rating, a common NEMA type is the 4X. NEMA 4X enclosures are suitable for either indoor or outdoor usage and protect equipment against water and windblown foreign objects.

To best match the NEMA type that your enclosure will need to weather its environment, consult your enclosure provider with the specifics of your application and the environment in which your enclosure will be placed.

Customization
Will your application require your enclosure to have holes or slots? Before making a purchase, make sure that the enclosure manufacturer can customize any machined slots or holes to fit your unique application requirements. At Integra Enclosures, we can make these modifications at our facility according to customer specs before shipping the product out. CNC machine cut outs, custom back panels and drilling holes are other configurability options that can be utilized to build your perfectly-tailored box. Ask your enclosure source for CAD drawings: any manufacturer should be able to provide the drawings so that you can easily specify your modifications.

Appearance
Maybe it seems trivial, but why not make sure your electrical enclosure fits visually – not just spatially – in its environment? Many enclosure manufacturers are now offering custom colors to help you blend your box to its surroundings. A clean, sleek design will accent your application environment, rather than pollute it. So when searching for the right enclosure, appearance matters! Don’t settle for good equipment protection that’s a bad eyesore.
Mounting Options
One of the most important questions to ask before selecting an enclosure is, “How easy will it be to install panels in the enclosure exactly where I need them?” Don’t trap yourself in a box by purchasing an enclosure with limited mounting options. At Integra Enclosures, our well-designed enclosure feature plenty of options for mounting back panels, face plates, circuit boards or any other component that needs to be secured.

Materials

Three main categories of enclosure material are available on the market: metal, fiberglass and polycarbonate. Integra manufactures polycarbonate enclosures both because of its strength, impact resistance and ability to weather harsh environments. There has been some confusion about whether or not polycarbonate enclosures can be used for outdoor applications:  let’s set the record straight now!  All materials, including sensitive and delicate electrical equipment, can be safely housed—even in outdoor conditions—in polycarbonate enclosures. An added benefit of the thermoplastic enclosures is that they are non-corrosive, non-conductive and lighter compared to steel.

Frame

Another important factor to consider when choosing an enclosure is its construction. While some enclosures are bolted together at the edges of panels, many molded plastic enclosures don’t require bolts because they can be manufactured seamlessly. So when you are deciding which enclosure to go with, the key is to know the demands of your application. If your new enclosure will be housed in a high-impact environment, a non-bolted style may be a better choice for you.

Hinges

Don’t underestimate this important facet of your enclosure. Before you buy your enclosure, make sure that the hinges are easily accessible and can be easily replaced when necessary. Hinges should also allow a wide angle door swing. Your enclosure’s door swing should open at least 180°.  However, an even wider angle — up to 225° — may be an important advantage when you need to service the equipment stored inside your enclosure. Both metallic and non-metallic hinges are available. Whichever option you choose, make sure that your hinges are durable enough to handle the rigors of heavy use.

Next post will cover important checklist items for your enclosure manufacturer. Stay tuned!

There are many important differences that set polycarbonate enclosures apart from enclosures made of fiberglass.  The most important differences are:  strength, durability and modifiability.

Need to visualize the difference? Check out our neat chart.

Strength
Polycarbonate enclosures are over four times stronger than fiberglass enclosures.  Polycarbonate enclosures can withstand over 900 pounds of impact, while the impact resistance of fiberglass enclosures is considerably less:  only 225 pounds of impact.

Durability
Polycarbonate enclosures will withstand direct exposure to UV light without deteriorating or fading in color. When fiberglass enclosures are exposed to UV light, their fiberglass materials begin to bloom and deteriorate, and their color fades.

Every polycarbonate enclosure manufactured by Integra is NEMA 4X rated, which means it is watertight and able to withstand direct water spray. Integra also produces a special IP66 rated enclosure series that can be fully submersed in water without deterioration and that can be marine-friendly (salt water resistant).

Modifiability
Polycarbonate enclosures are easy to customize and modify. Many times when an enclosure is installed, it needs to be modified, which involves cutting a hole in the enclosure or changing the material in some way. When fiberglass is modified, it gives off a very dangerous, fine dust that is irritant to the skin and can be dangerous to inhale. This dust is also very difficult to clean up because of how fine it is. However, polycarbonate enclosures produce small, safe curls of material that can be easily swept away and are not dangerous to inhale or touch.

Additionally, fiberglass, which is made up of interwoven fibers, is much more likely to splinter when they are being modified.  However, polycarbonate enclosures cut cleanly and easily, making them much easier to modify.

A Brand-New Solution to the US Market

We have exciting news!  Integra has just released the newest addition to our Genesis line:  a 24x24x10 enclosure product!  We are very excited because with this new addition, we are the industry leaders of the US market:  we are the first to release a product of this kind and specification here in the US.

There has been a growing demand for larger enclosure options, specifically among remote monitoring and energy industries, and Integra has worked to be the first to respond to this demand.

Jim McWilliams, Integra president, explains why we have added the new 24x24x10 enclosure products.  “We pride ourselves on staying in touch with our customers and knowing the demands of their industries, and we are constantly exploring how we can serve our customers better.”

Some of the standout features of the new 24x24x10 enclosures:

• -High-impact, UV-resistant polycarbonate materials
• -Flexible interior mounting, using Integra’s patented adjustable swing panel mounting system
• -Multiple bosses on the product allow for easy installation of devices and DIN rails

President McWilliams also said that Integra will continue to work to offer more exciting and innovative products as new needs arise.