In the world of electrical systems, enclosures, and industrial equipment, ensuring protection against dust, water, and other environmental factors is critical. This is where IP ratings come in. If you have ever noticed designations like IP55, IP67, or IP20 on a piece of equipment, you’ve seen the international standard that indicates how well an electrical or mechanical product is protected from solids and liquids.
For manufacturers, engineers, and even end-users, understanding IP ratings is essential to choosing the right product for specific applications. Making the wrong choice can lead to safety hazards, costly downtime, and reduced equipment life span.
In this blog, we’ll break down the concept of IP ratings, how they are classified, what each number means, and most importantly, how you can select the right protection level for your electrical panels, control systems, and industrial equipment.
What Are IP Ratings?
IP (Ingress Protection) ratings are defined by the International Electrotechnical Commission (IEC) standard 60529. The purpose of these ratings is to provide clarity on how resistant an enclosure or device is against the intrusion of solid objects (like dust and debris) and liquids (such as water).
Instead of using vague terms like “waterproof” or “dust resistant,” IP ratings offer a standardized code that can be universally understood.
An IP rating typically looks like this: IPXY
- The first digit (X) refers to solid particle protection.
- The second digit (Y) refers to liquid ingress protection.
For example:
- IP20 → Limited protection against solid objects, no protection against water.
- IP65 → Dust-tight and protected against low-pressure water jets.
- IP68 → Dust-tight and protected against continuous submersion in water.
Breakdown of IP Rating Digits
1. First Digit – Protection Against Solids
The first digit ranges from 0 to 6, indicating levels of protection against dust, tools, and accidental contact.
- 0 – No protection against contact or objects.
- 1 – Protection against objects >50 mm (e.g., accidental touch by hand).
- 2 – Protection against objects >12.5 mm (fingers).
- 3 – Protection against objects >2.5 mm (tools, thick wires).
- 4 – Protection against objects >1 mm (small wires).
- 5 – Dust protected (not fully dust-tight, but limited ingress won’t interfere).
- 6 – Dust-tight (complete protection).
2. Second Digit – Protection Against Liquids
The second digit ranges from 0 to 9, representing protection against water.
- 0 – No protection.
- 1 – Protection against dripping water.
- 2 – Dripping water, tilted at 15°.
- 3 – Spraying water at up to 60° angle.
- 4 – Splashing water from any direction.
- 5 – Water jets from a nozzle.
- 6 – Powerful water jets, heavy seas.
- 7 – Temporary immersion up to 1m.
- 8 – Continuous immersion beyond 1m.
- 9K – Protection against high-pressure, high-temperature water jets.
Video Guide for Quick Understanding
We understand that sometimes technical charts can be overwhelming. This short explainer video breaks down what IP rating means in real-world applications.
👉 Watch the IP Rating Explained Video Here (https://www.youtube.com/shorts/DwSKkJVJ64o?si=blbTsw6SIJJvuK9u)
This video makes it easier to understand the differences between IP44, IP65, IP67, and IP69K, allowing you to quickly identify the protection level that best matches your project’s needs.
Why IP Ratings Matter
Selecting the right IP rating is not just about durability—it’s about safety, compliance, and operational reliability. Here’s why it matters:
- Electrical Safety – Incorrect enclosures can expose live components to moisture or dust, creating shock and fire hazards.
- Equipment Longevity – The right protection ensures components remain operational for longer, reducing maintenance and replacement costs.
- Regulatory Compliance – Many industries must comply with IP rating standards to meet workplace safety laws.
- Operational Continuity – Preventing equipment failure avoids downtime in critical systems.
Common IP Ratings and Their Applications
Here are some of the most widely used IP ratings in industrial and commercial environments:
- IP20: Basic protection, often used for indoor electrical devices that don’t face moisture.
- IP44: Protection against splashes of water—common for bathroom fittings and outdoor lighting.
- IP55: Dust protected and resistant to water jets—used in many industrial electrical enclosures.
- IP65: Dust-tight and resistant to low-pressure water jets—ideal for outdoor equipment.
- IP66: Dust-tight and resistant to strong water jets—used in harsher industrial environments.
- IP67: Dust-tight and immersion-proof up to 1 meter—commonly used in outdoor and marine equipment.
- IP68: Dust-tight and resistant to long-term submersion—used in specialized underwater applications.
- IP69K: Maximum protection against dust and high-pressure washdowns—widely used in food processing plants and heavy industry.
Factors to Consider When Choosing the Right IP Rating
When selecting the appropriate IP rating for electrical panels, control systems, or industrial enclosures, several factors should be kept in mind:
1. Environment of Installation
- Indoor offices may require only IP20–IP44.
- Outdoor or dusty environments may require IP55–IP66.
- Marine or submerged conditions require IP67–IP68.
2. Level of Exposure
- Will the equipment face rain, hose-down cleaning, or immersion?
- Will it be in direct contact with dust, sand, or chemicals?
3. Regulatory Standards
Industries such as oil & gas, food processing, and pharmaceuticals often require compliance with specific IP ratings to ensure worker and process safety.
4. Maintenance Requirements
Higher IP ratings may reduce maintenance needs but can increase costs. Balance the protection level with operational needs.
5. Cost vs Protection
While IP68 offers top-tier protection, it may not be necessary for an indoor factory environment. Choosing the right balance avoids overspending.
Real-World Applications of IP Ratings
- Smart Factories & Industry 4.0: With the rise of Industrial IoT devices and automation panels, choosing the correct IP rating is critical to prevent system failures.
- Renewable Energy Plants: Solar inverters and wind turbines require IP65 or higher due to exposure to dust and weather.
- Data Centers: Often use IP20–IP40, as they operate indoors with climate control.
- Food & Beverage Industry: Equipment frequently exposed to washdowns requires IP69K.
- Construction & Mining: Harsh, dusty, and wet conditions call for IP66 or IP67 enclosures.
Mistakes to Avoid When Selecting IP Ratings
- Overestimating Needs – Paying for IP68 when IP55 would suffice leads to unnecessary costs.
- Underestimating Conditions – Choosing a low IP rating for outdoor use can result in frequent equipment failures.
- Ignoring Future Expansion – Systems may later be relocated to harsher environments. Choosing a slightly higher rating ensures future flexibility.
- Not Consulting Experts – Always consult enclosure and panel experts to align ratings with industry standards.
Conclusion
IP ratings provide a clear, standardized way to evaluate and select protection levels for electrical and industrial equipment. From dust and debris to powerful water jets and submersion, the right rating ensures safety, efficiency, and reliability.
When choosing an enclosure for electrical panel integration or control systems, consider the installation environment, exposure risks, compliance requirements, and cost-effectiveness. Doing so will help ensure long-term operational success while minimizing maintenance costs and downtime.
At Balaji Switchgears, we provide high-quality switchgear solutions, electrical panels, and enclosures that meet international IP rating standards. Our expertise ensures that industries can operate with confidence—knowing their equipment is safe, compliant, and built for maximum performance. Whether it’s IP55 panels for industrial plants or IP67 enclosures for outdoor applications, Balaji Switchgears delivers trusted solutions tailored to your needs.