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What is SCADA? A Simple Guide to Supervisory Control and Data Acquisition
Ever wondered how water treatment plants keep their operations running 24/7? Or how one operator can monitor hundreds of pumps
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How to Choose the Right HMI Panel for Your Industrial Application
In modern industrial automation, the Human Machine Interface (HMI) panel plays a critical role. These devices are the bridge between operators and machines, giving users visibility and control over processes in real time. Whether it’s monitoring production lines, adjusting setpoints, or reacting to alarms and system trends, the HMI panel is essential to keeping operations running smoothly and efficiently.
At Mizen Automation, we help businesses choose the right automation equipment, including HMI panels, tailored to their specific environment and needs. In this article, we’ll guide you through the key features to consider when selecting an HMI and highlight leading manufacturers and models worth looking at.
What is an HMI Panel?
An HMI panel is a user interface that connects operators to the machinery and control systems in a facility. It provides a graphical representation of real-time data, allowing operators to monitor performance, issue commands, and diagnose problems. HMIs range from simple text displays to high-resolution touchscreen panels capable of running complex applications.
Most industrial sites use multiple HMI panels, installed at strategic points throughout the plant. Each panel is customised to display relevant information for that location, whether that’s motor speeds, temperature readings, alarms, or production metrics.
The right HMI setup not only improves operational efficiency but also reduces downtime by enabling quick troubleshooting and faster response times.
Key HMI Features to Consider
When selecting an HMI panel, you’ll need to consider a range of technical and practical factors.
Display Size
One of the first choices is screen size. HMI panels come in various sizes, usually ranging from 3 inches up to 25 inches or more. A compact panel might be ideal for a control cabinet with limited space, while larger panels are better suited to applications that require detailed process visualisation or multiple data points displayed simultaneously.
Touchscreen vs. button-operated
Touchscreen HMIs offer flexibility, intuitive navigation, and faster interaction. However, in harsh environments or where gloves are used, tactile buttons or hybrid options (touchscreen plus function keys) might be more suitable. While touchscreens typically cost more, their ease of use can justify the investment in many applications.
Colour or monochrome display
Colour screens make it easier to differentiate alarms, trends, and process states at a glance. Monochrome HMIs are more basic but can still be effective in simple applications, especially where budget constraints exist.
Screen resolution
Resolution impacts how clearly information and graphics are displayed. Higher-resolution panels are essential for complex SCADA or graphical applications, while simpler screens may suffice for basic data monitoring.
Mounting type
Consider how the HMI will be installed. Will it be panel-mounted into a cabinet, placed on a pedestal, or used as a handheld unit? Mounting style will influence usability, safety, and space requirements.
Environmental protection
Industrial environments can be harsh. HMIs should have the appropriate IP rating to protect against dust, water, vibration, and chemicals. For food, pharmaceutical, or outdoor use, go for IP65 or higher. Stainless steel options are also available for cleanroom or washdown environments.
Connectivity and interfaces
Look at the communication protocols supported by the HMI. Does it offer Ethernet/IP, Profinet, Modbus, or serial communication? Check for compatibility with your PLCs and other equipment. Some panels include multiple ports for connecting barcode scanners, sensors, or external storage devices.
Software compatibility
Ensure the HMI supports your preferred programming platform. For example, Siemens HMI panels work seamlessly with TIA Portal, while Allen-Bradley’s HMIs integrate with FactoryTalk View. Also consider whether you need support for OPC, HTML5, or other specific applications.
Custom application support
Do you need to run custom software like barcode scanning, inventory tracking, or remote access tools? If so, choose a panel that supports these capabilities or includes a built-in operating system like Windows CE or Linux.
Operating system
Some HMIs are standalone units running vendor-specific software, while others operate on standard OS platforms such as Windows or Android. The right choice depends on the complexity of your application and the level of control you require.
HMI Panel Application Examples
Understanding where and how HMI panels are used can help you choose the right one for your specific needs. Here are a few real-world application scenarios where HMI panels play a key role:
1. Packaging Line Control
In a food manufacturing plant, operators use a 10” colour touchscreen HMI mounted directly on the packaging line. This panel displays real-time data on machine status, production speed, and jam detection. It allows staff to quickly adjust setpoints for conveyors and label printers, and to stop the line in case of a fault. The touchscreen interface simplifies training for new operators and reduces downtime.
2. Tank Farm Monitoring
At a chemical processing site, rugged outdoor-rated HMIs are mounted near each tank in the farm. These units have IP65 protection and built-in Wi-Fi to connect with the plant’s SCADA system. Operators use the panels to view tank levels, monitor temperature and pressure, and receive alarms when thresholds are breached. Wireless connectivity eliminates the need for costly cabling across large outdoor areas.
3. Remote Access in Water Treatment
A council-operated water treatment facility uses panel-mounted HMIs in pump stations across the region. These HMIs are integrated with cellular modems, allowing technicians to view status and make adjustments remotely. This setup reduces the need for frequent on-site visits and ensures timely responses to faults or changing conditions.
4. Pharmaceutical Cleanroom Operations
In a pharmaceutical plant, stainless steel HMIs are used inside cleanrooms. These units support multi-touch operation through gloves and meet strict hygiene and IP66 standards. Operators use them to view batch information, enter process data, and initiate CIP (Clean-in-Place) cycles. Secure access control ensures only authorised personnel can make changes to critical settings.
5. Warehouse Automation
A logistics warehouse uses HMI panels mounted on forklifts and workstations. These units interface with barcode scanners and WMS (Warehouse Management System) software. They guide operators through picking tasks, update inventory levels in real time, and display routing information. Ruggedness and bright displays make them suitable for high-movement and varied lighting conditions.
6. Hazardous Environment Control
In a mining facility, explosion-proof HMI terminals control ventilation systems and monitor gas levels underground. These models feature reinforced enclosures and fail-safe communication protocols. Operators rely on them to maintain safe air quality and respond to emergency alerts, even in harsh underground environments.
Top HMI Brands and Their Product Ranges
Choosing a trusted HMI brand is crucial for performance, reliability, and future support. Here are some of the top HMI panel brands we supply and recommend at Mizen Automation:
Siemens offers one of the most comprehensive HMI portfolios. Their Basic Panels are ideal for simple applications and cost-effective integration with Siemens PLCs. Comfort Panels provide advanced functionality, better graphics, and are available in a range of sizes. The latest Unified Comfort Panels support HTML5 graphics and include built-in security features, making them suitable for modern networked environments.
The PanelView Plus series is a favourite in facilities using Rockwell controllers. PanelView Plus 7 offers advanced visualisation, Ethernet/IP connectivity, and models suitable for cleanroom and hazardous areas. The rugged ArmorView range is designed for demanding environments and supports a fault-tolerant ring network architecture.
Weintek HMIs are a reliable and cost-effective option for a wide range of automation systems. Their cMT Series supports IIoT integration, remote access, and multiple protocols, making it a flexible choice for both basic and advanced setups.
Known for rugged and user-friendly HMIs, Maple Systems offers models with Wi-Fi connectivity, high-brightness displays, and flexible mounting options. These panels are ideal for remote locations like tank farms or outdoor assets.
Red Lion’s HMIs are well-suited to remote monitoring and industrial data acquisition. Their Graphite Series combines touchscreen functionality with strong environmental protection, making them suitable for tough industrial settings.
Making the Right Choice
There’s no one-size-fits-all HMI panel. The best solution depends on the nature of your application, environmental conditions, the control system you’re using, and your budget.
At Mizen Automation, we take the time to understand your requirements and recommend the best-fit HMI solution. Whether you need a high-end graphical interface or a rugged, basic display for harsh conditions, we’ve got you covered. We stock and source a wide range of new, obsolete, and spare HMI panels from trusted global brands.
Need help choosing the right HMI for your operation?
Contact our expert sales team today and let us help you find the perfect match.
This article includes insights adapted from RealPars, a leading resource in industrial automation training.
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