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Duke Control Systems Blog

Industrial Automation
Insights & Technical Guides

Practical insights, technical guides and industry thinking from the Duke Control Systems engineering team — covering PLC programming, robot programming, virtual commissioning and industrial automation for UK manufacturers.

Latest Articles

From the Duke Engineering Team

Unplanned downtime and OEE losses from ageing industrial controls
PLC Control Systems

Unplanned Downtime Is an Obsolescence Problem

How to cut OEE losses from ageing controls, before they cost you.

July 2026 · 7 min read
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Flexible engineering resource for manufacturers
Engineering Resource

Flexible Engineering Resource: Scale Your Team Without the Overhead

Why more manufacturers are turning to flexible engineering resource instead of the agency call, and what you actually get with it.

July 2026 · 6 min read
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Control panel build for UK manufacturers
Electrical Design & Panel Build

Control Panel Build for UK Manufacturers: What to Expect

What the process looks like, what it costs, and what to tell your supplier to get the right result.

June 2026 · 8 min read
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Warehouse automation on a budget for SMEs
Logistics & Warehousing

Warehouse Automation on a Budget: What SMEs Can Afford

Practical automation options for small and medium UK warehouses. What you can realistically afford, where to start, and how to avoid overspending.

June 2026 · 8 min read
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Factory automation cost guide UK
Project Planning

How Much Does Factory Automation Cost in the UK?

Realistic cost ranges by project type — PLC retrofits, robotic cells, conveyor systems — and what drives the price up or down.

June 2026 · 8 min read
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Virtual Commissioning
Virtual Commissioning

Virtual Commissioning Explained: Cut On-Site Startup Time by 80%

Testing your automation system in simulation before installation, how it works, when to use it, and what to ask your integrator.

May 2026 · 7 min read
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Cobots vs Traditional Robots
Robotics & Automation

Cobots vs Traditional Robots: Which Is Right for Your Production Line?

A practical guide to understanding the difference between cobots and traditional robots, and which is right for your facility.

April 2026 · 7 min read
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How to Choose an Automation Integrator
Buyer's Guide

How to Choose an Automation Integrator: UK Buyer's Guide

What to look for, what to ask, and what the warning signs look like before you commit to an integrator.

April 2026 · 9 min read
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Modernise Legacy Control Systems: Safe Obsolete PLC Upgrades
PLC Control Systems

Modernise Legacy Control Systems: Safe Obsolete PLC Upgrades

Ageing PLCs pose real risk to production reliability. How to approach a legacy upgrade safely with minimal disruption.

April 2025 · 6 min read
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Palletising Robots in the FMCG Sector
FMCG Automation

Palletising Robots in the FMCG Sector

How palletising robots improve throughput, safety and flexibility for fast-moving consumer goods manufacturers.

March 2025 · 6 min read
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Global Robot Density 2025: Top Countries vs the UK
Industry Insight

Global Robot Density 2025: Top Countries vs the UK

South Korea leads with 1,220 robots per 10,000 workers. Where does the UK rank and what does it mean for manufacturers?

March 2025 · 5 min read
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Why Your Robot Feels More Like a Liability Than an Asset
Robot Programming

Why Your Robot Feels More Like a Liability Than an Asset

Unplanned stops, safety trips and missed cycle times — is your robot a bottleneck? Here's how to fix it.

March 2025 · 6 min read
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UK Automotive Industry Post-Brexit: EV Shift & Future Outlook 2026
Automotive

UK Automotive Industry Post-Brexit: EV Shift & Future Outlook 2026

From Daimler to gigafactories — how automation is helping UK plants stay competitive in the EV era.

February 2025 · 7 min read
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Reviving Legacy PLCs: Upgrade Obsolete Controls Without Downtime
PLC Control Systems

Reviving Legacy PLCs: Upgrade Obsolete Controls Without Downtime

Over 50% of UK factory controls are over 12 years old. Proven strategies for upgrading without halting production.

February 2025 · 7 min read
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2026 UK Labour Crisis: Why Factories Need Robots & Automation Now
Industry Insight

2026 UK Labour Crisis: Why Factories Need Robots & Automation Now

49,000 manufacturing vacancies and rising. How automation is helping UK factories close the gap.

February 2025 · 6 min read
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Industry 4.0 Reality: The 80/20 Rule for UK Manufacturers
Industry 4.0

Industry 4.0 Reality: The 80/20 Rule for UK Manufacturers

Forget million-pound MES platforms. How to deliver 80% of Industry 4.0 gains from 20% of targeted improvements.

January 2025 · 6 min read
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Unlock Hidden Capacity: The Value of a Free Production Line Review
Production Optimisation

Unlock Hidden Capacity: The Value of a Free Production Line Review

Independent expert eyes often spot inefficiencies that daily operators miss — and what results clients have achieved.

January 2025 · 5 min read
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Palletising Robots: Fast ROI for Any End-of-Line
Robotic Palletising

Palletising Robots: Fast ROI for Any End-of-Line

25–35% labour savings and ROI within 18 months — integrating with your existing line without expensive rebuilds.

January 2025 · 6 min read
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