Key Highlights
- Ethernet-based networks now account for 76% of new installations as legacy fieldbus systems decline to just 17%.
- Open protocols like OPC UA and MQTT enable integration across multi-vendor systems, reducing costs and breaking down data silos.
- Cybersecurity has become critical as hyperconnectivity increases risk, requiring network segmentation and zero-trust architectures for protection.
Industrial networks are the backbone of control systems, enabling communication between devices such as controllers, sensors, actuators and enterprise systems. As industries embrace digital transformation, the need for robust, scalable and intelligent connectivity has never been greater. That’s why the landscape of industrial connectivity is being reshaped by technological innovation, economic pressures and evolving operational requirements.
According to HMS Networks' 2025 report, Ethernet-based industrial networks account for 76% of new node installations, a 5% increase from 2024. Meanwhile, legacy fieldbus technologies have declined to 17%, with wireless systems remaining at 7%. This trend underscores the industry's move toward flexible and scalable Ethernet solutions, reflecting the preference for deterministic communication protocols that support real-time control and data exchange.
Wireless technologies, though not dominant, play a crucial role in applications requiring mobility, flexibility or connectivity in hard-to-reach areas, such as with automated guided vehicles (AGVs) and wireless sensors.
5G is also worth a mention here, as research shows that it can be advantageous in terms of addressing latency and bandwidth issues. However, there are difficulties with 5G that still need to be ironed out, such as infrastructure complexity and industrial environment challenges. In my opinion, for batch manufacturing and automation, 4G still dominates but 5G is more strategic to future plans.
The rise of hyperconnectivity
The convergence of information technology (IT) and operational technology (OT) has been a trend for the last number of years, but it really became a defining trend in 2025. The reason: industrial networks are evolving to support hyperconnectivity, where devices and subsystems are interconnected across multiple layers of automation.
Within batch manufacturing sites, there is also a growing demand for event-driven data in real time. ISA-95 & ISA-88 are instrumental to defining a hierarchical structure for contextualizing event-driven data.
Hyperconnectivity has some specific benefits for manufacturers, such as continuous real-time monitoring of production processes, instant data transmission between systems and machines as well as scalable integration of heterogeneous devices and protocols. Components like Ethernet-APL (advanced physical layer), time-sensitive networking (TSN) and edge-based platforms are facilitating this convergence, ensuring deterministic communication and enabling centralized data management.
The impact of open protocols and data fabrics
The push for interoperability and standardization is driving the development of open protocols and communication standards in industrial networks. Protocols such as OPC UA and MQTT enable seamless integration of devices and systems from different vendors. This interoperability enhances flexibility, reduces integration costs and promotes innovation. Meanwhile, the standardization offered by OPC UA and MQTT creates a common language and structure for data, preventing silos and errors.
As batch manufacturers tend to have a mix of control systems, OPC UA and MQTT are key enablers for retrieving the data and sending it up towards the enterprise layer for data analytics.
Batch manufacturers produce so much data from their process that it can be difficult to collate, contextualize and visualize it all. An emerging trend here involves the use of industrial data fabric, which integrates data from multiple sources into one area for users to analyze within one place in the cloud. The industrial data fabric opens the door for advanced analytics applications related to predictive maintenance, quality control and general operational optimization.
Hyperconnectivity offers specific benefits for manufacturers, such as continuous real-time monitoring of production processes, instant data transmission between systems and machines as well as scalable integration of heterogeneous devices and protocols.
Within batch manufacturing sites, there is also a growing demand for event-driven data in real time. ISA-95 & ISA-88 (for batch context) is also instrumental in defining a hierarchical structure for contextualizing event-driven data, typically organized as:
Enterprise → Site → Area → Process Cell.
This hierarchy supports consistent data modelling and integration across digital systems.
Industy’s ongoing industrial connectivity challenges and opportunities
However, with this increased connectivity comes heightened risk. OT cybersecurity is now a fundamental requirement for industrial networks. Organizations must protect systems and data from internal threats and external attacks, especially as remote access and cloud integration become more common. Some key strategies here include network segmentation, the use of zero-trust architectures and compliance with standards such as ISA/IEC 62443.
Despite the progress within industrial connectivity, several challenges remain:
- Legacy system integration continues to be a hurdle within brownfield sites. While many have OPC UA and MQTT to help communicate with multiple systems, not all legacy systems support these protocols.
- High implementation costs for advanced technologies like TSN and 5G.
- Reliable source of data including redundancy for analytics on the enterprise layer. It can be a challenging with some systems to have hot failover that produce no data gaps.
However, these challenges also present opportunities:
- System designs are now focusing on modular and scalable solutions that can ease integration.
- For batch manufacturers, focusing on reliable data is crucial. This involves creating data sources with redundancy for enterprise-level analytics and developing systems that ensure hot failover capabilities can prevent data gaps and maintain continuous data flow.
Looking ahead, industrial control systems environment will continue to evolve toward:
- More IT/OT convergence.
- Edge-to-cloud architectures for real-time analytics.
- Adoption of industrial data fabrics.
More industrial networking insights from Automation World:
About the Author
Patrick Corbett
Patrick Corbett is senior automation data systems engineer at Eli Lilly and Company, senior member of the International Society of Automation (ISA) and president of the ISA Ireland Section.
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