How to Choose the Right Wire Harness for Foodservice Equipment

In commercial foodservice environments, equipment reliability is not optional. From cooking lines and refrigeration units to beverage systems and prep stations, electrical performance plays a crucial role in ensuring operations run smoothly. 

At the heart of many of these systems is a component that often goes unnoticed until something fails: the wire harness. Choosing the right wire harness for foodservice equipment involves thoughtful design, material selection, durability planning, and customization to withstand demanding operating conditions. 

This article breaks down what foodservice OEMs and equipment designers should consider when selecting or designing wire harnesses, and why custom assemblies often deliver better long-term performance than off-the-shelf solutions.

Why Wire Harnesses Matter in Foodservice Equipment

Foodservice equipment operates in one of the most challenging environments for electrical systems. High heat, moisture, vibration, grease, and frequent cleaning cycles all place stress on wiring and connections. A poorly designed wire harness can lead to intermittent failures, shortened equipment life, increased service calls, and costly downtime.

Wire harnesses help organize, protect, and route electrical wiring within equipment. When properly engineered, they:

• Improve reliability and consistency of electrical connections
• Reduce installation and assembly time
• Protect wiring from environmental stress
• Simplify troubleshooting and maintenance

In foodservice applications, these benefits directly impact uptime, safety, and customer satisfaction.

What Makes Foodservice Applications Unique?

Before selecting a wire harness, it’s important to understand how foodservice environments differ from other commercial or industrial settings.

1. High Heat Exposure

Cooking equipment such as ovens, griddles, fryers, and warming units exposes wiring to sustained high temperatures. Wire insulation and jacketing must be selected to prevent cracking, melting, or signal degradation over time.

2. Moisture and Washdowns

Water exposure is common in kitchens due to cleaning routines and the use of steam-producing equipment. Wire harnesses must be designed to resist moisture intrusion, corrosion, and degradation from repeated exposure.

3. Tight Spaces and Complex Layouts

Foodservice equipment often packs multiple electrical and mechanical components into compact enclosures. Harnesses must be designed for precise routing to avoid interference, pinching, or strain on connectors.

4. Constant Use and Vibration

Many foodservice systems run continuously or cycle frequently throughout the day. Vibration and repetitive movement can stress connections if strain relief and routing are not properly designed and implemented.

Key Design Considerations for Foodservice Wire Harnesses

Selecting the right wire harness involves evaluating several critical factors that directly influence performance and longevity.

Material Selection for Insulation and Jacketing

Insulation materials play a major role in how well a wire harness performs in harsh kitchen environments. 

Common considerations include:

• Heat-resistant insulation to handle elevated temperatures
• Durable jacketing to resist abrasion and chemical exposure
• Flexible materials that allow routing in tight spaces without stress

Choosing the right combination of materials helps prevent premature wear and electrical failure.

Connector Quality and Fit

Connectors are often the first failure point in foodservice equipment. A properly designed wire harness uses connectors that:

• Maintain secure electrical contact over time
• Withstand vibration and movement
• Fit precisely within the equipment layout

Custom harnesses allow connectors to be selected and positioned specifically for the application, reducing the risk of loose or misaligned connections.

Strain Relief and Routing

Without proper strain relief, wires can pull against terminals and connectors, leading to intermittent failures or complete disconnection. 

A well-designed harness accounts for:

• Movement during operation or service
• Entry and exit points through panels or enclosures
• Natural bend radius of the wire

Intentional routing reduces stress and improves durability.

Labeling and Organization

Clear labeling and consistent organization make installation and service easier. For OEMs, this means:

• Faster assembly during manufacturing
• Reduced errors during installation
• Simplified troubleshooting for service technicians

Custom harness assemblies can be labeled and bundled to match specific build requirements.

Common Foodservice Equipment Applications for Wire Harnesses

Wire harnesses are used throughout foodservice equipment, supporting a wide range of functions.

Cooking Equipment

Harnesses power heating elements, control panels, sensors, and safety systems in ovens, ranges, fryers, and warmers.

Refrigeration Systems

Electrical connections support compressors, fans, lighting, thermostats, and control boards in refrigerators and freezers.

Beverage and Dispensing Equipment

Coffee machines, soda dispensers, and ice makers rely on harnesses to manage pumps, heating elements, and electronic controls.

Prep and Holding Equipment

From hot holding cabinets to prep tables, wire harnesses ensure consistent power delivery and system communication.

Each application presents unique challenges that are best addressed through customized design.

Off-the-Shelf vs. Custom Wire Harnesses

While off-the-shelf wire harnesses may appear convenient, they are rarely optimized for foodservice equipment environments.

Limitations of Standard Harnesses

• Generic lengths that require excess routing or modification
• Materials not suited for heat or moisture exposure
• Connector placements that don’t align with equipment layouts
• Increased installation time and error risk

Advantages of Custom Wire Harnesses

Custom assemblies are designed specifically for the equipment they support. Benefits include:

• Exact wire lengths and routing paths
• Purpose-selected materials for the operating environment
• Reduced assembly time and labor costs
• Improved reliability and lifespan

For OEMs, custom harnesses help ensure consistent quality across production runs.

CHG’s Approach to Foodservice Wire Harnesses

Component Hardware Group (CHG) works with OEMs to develop wire harness solutions that support performance-driven equipment design. Rather than offering one-size-fits-all products, CHG focuses on building assemblies that align with real-world operating demands.

Key aspects of CHG’s approach include:

• Collaborative design support to align harness design with equipment layout
• Scalable production for both low- and high-volume programs
• Integration with other CHG hardware and electrical components
• Consistent build quality to support long-term equipment reliability

For foodservice equipment, CHG’s harness manufacturing practices follow guidance from IPC/WHMA-A-620D Class 3. This is the industry’s standard for high-performance cable and wire harness assemblies used in harsh or critical environments. Class 3 assemblies are ideal for applications like commercial kitchen equipment, where consistent performance under heat, moisture, and vibration is essential.

Learn more about IPC/WHMA-A-620D Class 3 requirements →

CHG also collaborates with trusted brand partners across various electrical and hardware categories, enabling OEMs to source compatible components through a single supplier relationship.

Designing for Long-Term Performance

Foodservice equipment is expected to perform reliably for years to come. The right wire harness contributes to that goal by:

• Reducing electrical failures
• Minimizing service calls
• Supporting consistent performance under demanding conditions

By investing in thoughtful harness design upfront, OEMs can reduce the total cost of ownership and deliver better end-user experiences.

Final Thoughts: Choosing the Right Wire Harness Is a Strategic Decision

Selecting a wire harness for foodservice equipment is a strategic decision. The right design supports reliability, simplifies manufacturing, and protects the long-term performance of the equipment.

Custom wire harnesses enable OEMs to design with confidence, knowing that their electrical systems are built to withstand the harsh realities of commercial kitchens. 

With expertise across electrical components, custom assemblies, and foodservice hardware, CHG helps manufacturers build solutions that perform where it matters most.

We can help. Contact us today.