Industrial automation environments are known for their complex networks of equipment and machinery that, while essential for productivity, also generate substantial amounts of heat. High-current power cables, motor drives, programmable logic controllers (PLCs), and densely packed control wiring can contribute significantly to the temperature rise on the plant floor. When this heat is not effectively managed, it can lead to a host of problems, including the degradation of cable insulation, which can compromise the safety and efficiency of electrical systems. Additionally, elevated temperatures can adversely affect signal reliability, leading to erratic control signals and potential operational failures. Over time, the cumulative stress from heat can substantially shorten the lifespan of critical equipment, resulting in costly repairs and unexpected downtime. 

To combat these heat-related challenges, mesh cable trays have emerged as a highly effective solution for managing industrial power runs and control wiring. These trays allow for improved air circulation compared to traditional solid trays, which aid in dissipating heat more efficiently. When paired with PLTC (Power Limited Tray Cable) control cables and tray-rated power cables, mesh trays provide an optimal environment for electrical systems, ensuring that cables remain cool and functioning as intended. This combination not only promotes better thermal management but also enhances system reliability and longevity. 

Key Takeaways 

  • Heat buildup is a major risk factor in industrial power cabling 
  • Mesh cable trays allow superior airflow and heat dissipation 
  • Open-wire design reduces thermal stress on power and control cables 
  • PLTC cables benefit from cooler, more stable routing conditions 
  • Mesh trays protect Ethernet and fiber from heat-related degradation 
  • Powder-coated trays add durability for harsh manufacturing environments 

Why Heat Is a Critical Issue in Industrial Power Cabling 

Excess heat in cable pathways can lead to a host of serious issues that compromise both the integrity of the cables and the overall efficiency of electrical systems. One of the most critical concerns is insulation breakdown, which can occur when cables are subjected to prolonged exposure to elevated temperatures. This degradation not only shortens the lifespan of the cables, leading to premature failure, but it can also pose significant safety risks, such as electrical fires or equipment malfunctions.   

Traditional cable management systems, such as solid-bottom trays and enclosed conduit systems, often exacerbate these thermal challenges. By trapping heat within the pathways, they create a conducive environment for overheating, particularly in high-load industrial settings where equipment demands are substantial. This not only reduces safety margins but also increases the frequency of maintenance interventions, driving up operational costs.  

How Mesh Cable Trays Improve Heat Dissipation 

Mesh cable trays are engineered with a distinctive open-wire structure that significantly enhances airflow around the cables they support. This design feature is crucial in environments where heat generation is a concern, as it facilitates the dissipation of thermal energy that can accumulate around dense cable bundles. Unlike traditional solid trays that can trap heat, mesh trays create a more efficient cooling environment by allowing air to circulate freely around the cables. This is particularly beneficial for a variety of cable types, including industrial power cables, PLTC (Power-Limited Tray Cables) control cables, and high-performance Ethernet and fiber optic cabling. The ability of mesh trays to promote airflow is not just a minor advantage; it plays a critical role in ensuring that cables operate within their safe temperature ranges. 

Mesh Cable Trays for Industrial Power Runs 

Industrial power systems operate under rigorous conditions that impose significant demands on cable management solutions. These systems often involve high current loads, necessitating robust infrastructure capable of supporting continuous operation. Additionally, many industrial environments expose cables to harsh conditions, including extreme temperatures, moisture, chemicals, and physical wear and tear. As a result, the choice of cable management systems becomes crucial in ensuring not just operational efficiency but also safety and reliability. Properly designed cable management can prevent overheating, reduce wear, and minimize the risk of electrical faults, which are critical for maintaining productivity and safeguarding personnel and equipment. 

Supporting High-Current Power Runs Safely 

Industrial power distribution systems are critical for the smooth operation of various facilities, and they often involve high-current loads that can generate significant amounts of heat. In scenarios where power cables are bundled too closely together or enclosed within tight spaces, the heat produced can become a serious issue. This lack of adequate ventilation can lead to increased temperatures, which may result in derating where the cables must operate at lower capacities to prevent overheating and ultimately lead to costly downtime or even equipment failure. Therefore, ensuring proper heat dissipation is crucial for maintaining the reliability and efficiency of power distribution systems. 

Why Mesh Trays Are Ideal for Power Cables 

  • Improved airflow around high-amp conductors 
  • Reduced derating concerns due to heat buildup 
  • Easier inspection for overheating or damage 

Protecting PLTC Control Cables from Heat Stress 

PLTC, or Power-Limited Tray Cable, plays a crucial role in various industrial and commercial applications, particularly in automation control, signaling, and instrumentation systems. These cables are specifically designed to carry lower voltages, which makes them ideal for use in environments where safety and efficiency are paramount. The construction of PLTC cables typically includes multiple conductors insulated with materials that provide resistance to environmental factors, ensuring reliable performance over time.  

Mesh Trays Allow: 

  • Physical separation between control and power wiring 
  • Reduced radiant heat transfer 
  • Consistent operating conditions for sensitive signals 

Managing Ethernet and Fiber in High-Heat Environments 

Modern automation systems rely heavily on industrial Ethernet and fiber networks for real-time monitoring, SCADA, and IIoT connectivity. These technologies play a crucial role in facilitating real-time monitoring, enabling Supervisory Control and Data Acquisition (SCADA) systems, and supporting the Internet of Things (IoT) within industrial settings. The integration of these advanced networks allows for seamless communication between machinery, sensors, and control systems, ultimately enhancing operational efficiency, improving decision-making, and driving productivity. As industries continue to embrace automation, ensuring the integrity and performance of these networks is more essential than ever. 

Powder-Coated Mesh Trays: Built for Harsh Environments 

In industrial environments, the challenges extend far beyond just managing heat. Factors such as dust accumulation, oil spills, exposure to various chemicals, and constant vibration can significantly impact equipment performance and worker safety. Each of these elements can contribute to wear and tear on machinery and tools, making it essential for facilities to adopt solutions that can withstand these harsh conditions. For instance, dust can lead to clogs and overheating in machinery, while oil and chemicals can corrode surfaces and create hazardous working conditions.  

Scalable Design for Future Automation Growth 

As production lines continue to evolve, the demands placed on electrical systems are becoming increasingly complex. With the rise of advanced machinery and automation technologies, power loads are on the upswing, and cable density is reaching unprecedented levels. In this context, mesh cable trays offer a practical solution due to their inherently modular and scalable design.  

This adaptability allows facility managers and engineers to easily add new power or control circuits as needed, without the hassle of significant downtime. The structured layout of mesh trays not only accommodates the growing number of cables but also provides excellent airflow, which is crucial for preventing overheating and ensuring optimal performance. 

ShowMeCables delivers industrial cable management that keeps your systems cool, safe, and reliable. Our mesh cable trays boost airflow, reduce thermal stress on power and control lines, protect Ethernet and fiber, and stand up to harsh manufacturing environments with durable powder-coated finishes. 

ShowMeCables offers a full range of network connectivity and infrastructure solutions for small and medium-sized businesses. In addition, our customer-focused approach includes a same-day shipping policy and U.S.-based customer service support.  Questions? Please call us at +1 (866) 545-8420, email us or visit our contact page.   

Frequently Asked Questions  

Why do Mesh Cable Trays Dissipate Heat Better Than Solid Trays? 

Mesh trays allow air to circulate freely around cables, preventing heat from becoming trapped and reducing overall cable temperature. 

Are Mesh Trays Suitable for High-Current Power Runs? 

Yes. Mesh trays are ideal for industrial power cables because they reduce heat buildup and simplify inspection. 

Can PLTC Control Cables be Routed in Mesh Trays with Power Cables? 

Yes, when proper spacing or dividers are used to minimize heat transfer and electromagnetic interference. 

Mesh trays stand out as the superior choice for industrial power runs due to their exceptional heat dissipation capabilities and versatility. By allowing for better airflow and reducing the risk of overheating, they ensure that electrical systems operate efficiently and reliably. While traditional cable management solutions may still have their place, the advantages offered by mesh trays, such as ease of installation and maintenance, make them a practical investment for any industrial setting.