The modern factory floor creates an auditory blend of machinery noise and a steady flow of data. Operational technology (OT) systems no longer function in isolation from information technology (IT) systems. Instead, industrial ecosystems nowadays act as intricate networks connecting SCADA control centers with minimal temperature sensors found on refrigeration units. But with this complexity comes a challenge: What methods exist to oversee all systems while avoiding the pitfalls of using incompatible tools and creating blind spots?
Let me tell you a little secret that's not really a secret anymore: PRTG Network Monitor transformed from basic IT monitoring into a full-scale monitoring solution for Operational Technology (OT) environments. Your operations in food production, building automation systems, and industrial equipment maintenance gain complete visibility through PRTG monitoring.
Picture this scenario: The operation of your production line requires dozens of interconnected network components. Your SCADA system effectively tracks production equipment performance but you need monitoring capabilities for the network switches that enable communication between devices. Or for the environmental sensors ensuring optimal conditions? The need for separate monitoring tools for each system leads to a disjointed overview that turns troubleshooting into an extremely complex task.
Traditional monitoring systems have limited visibility into specific segments of the OT stack. SCADA systems work well for production process monitoring yet struggle with integrating modern IoT sensors. IT monitoring tools face challenges because they cannot understand industrial protocol languages. The lack of a unified monitoring system allows problems to remain hidden until they escalate into major system breakdowns.
As one maintenance supervisor at a food processing company put it:
Prior to adopting PRTG our network problems impacted production without any clear indication whether the fault was in the equipment or the network infrastructure. We were flying blind.
PRTG stands out in industrial monitoring because it supports communication across the full spectrum of protocols used in modern OT environments. PRTG's strength lies not only in its numerous sensors, but also in its ability to interpret various languages and bring all elements together into one cohesive view.
PRTG provides support for numerous industrial communication standards such as:
OPC Unified Architecture functions as the accepted universal standard for enabling industrial systems to work together. PRTG provides several OPC UA sensors capable of tracking server status and certificate expiration along with custom data points from OPC UA-compatible devices. You gain access to PLCs and other control systems including HMIs without needing complicated integration tasks.
PRTG provides custom sensors which enable legacy Modbus TCP devices and field equipment to monitor up to five metrics from any Modbus device. The ability to monitor outdated equipment like air conditioning systems and older industrial machines through custom sensors provides significant value because these devices often lack support for modern protocols.
The widespread adoption of Industrial Internet of Things (IIoT) devices on factory floors has made MQTT the preferred lightweight messaging protocol. MQTT sensors in PRTG monitor broker status and topic subscriptions, analyze message patterns, and provide optimal oversight of distributed sensor networks and edge devices.
With support for multiple protocols, PRTG provides complete monitoring visibility, from central control rooms to edge network devices. Users can avoid toggling between different monitoring tools and questioning the connection between alerts from independent systems.
Now we'll explore how this complete monitoring solution performs in an actual operational environment. The global food processing company adopted PRTG for monitoring their cold chain operations which consisted of refrigeration units and conveyor belts together with humidity sensors.
The firm deployed Modbus TCP sensors for refrigeration equipment monitoring while using MQTT sensors to gather data from wireless temperature and humidity sensors across their facility. PRTG enabled them to receive immediate alerts whenever temperatures exceeded safe limits thus ensuring compliance with food safety standards and avoiding expensive product spoilage.
The team demonstrated innovation by linking their PRTG system to their SCADA platform through the PRTG OPC UA Server. Operators gained visibility of IT infrastructure alerts including network and server problems on their SCADA HMI together with production monitoring information. An alert notified operators through their SCADA interface of impending network switch failure which supported the essential refrigeration controller enabling them to act to protect production processes.
A maintenance supervisor from another firm that uses PRTG monitoring systems describes how their PRTG sensors predict potential failures. The alert initiates processes to inspect factory floor conditions and restart equipment to prevent minor faults from escalating into major issues.
PRTG's built-in OPC UA Server capability stands out as one of the strongest features for operational technology environments. The extension enables SCADA and HMI systems to access real-time sensor data from PRTG which leads to improved process control without implementing disruptive changes to existing systems.
Here's how it works:
Industries that depend on continuous operation gain significant benefits from this integration. A network outage that disrupts refrigeration monitoring systems during food production can result in inventory spoilage. When operators integrate IT alerts into the SCADA system they can address infrastructure problems before they affect production.
As one system integrator noted:
PRTG OPC UA Server functionality which brings IT monitoring data and alarms into the SCADA system as a unified endpoint can potentially save human lives in optimal conditions.
PRTG's end-to-end monitoring capabilities offer multiple advantages that extend past basic alert mechanisms.
Utilizing a single platform for your devices and sensors removes the necessity to handle multiple monitoring tools. The system reduces operational complexity while also cutting down on training needs and licensing expenses.
Industries including food production and pharmaceuticals must follow regulations that enforce proper environmental conditions. PRTG provides comprehensive logs and reports to support audit compliance verification.
Automation of field device data collection allows technicians to dedicate their time to maintenance tasks and system enhancements instead of performing regular inspections. Automated monitoring enabled a food producer to reduce daily work time by two hours.
Historical data gathered by PRTG supports trend analysis for detecting equipment at risk of failure. Predictive maintenance replaces reactive methods to minimize downtime and prolong equipment lifespan.
Inventory your OT assets: You must first identify all components in your OT environment before effective monitoring can begin. Compile an exhaustive list of industrial devices that includes PLCs, RTUs, HMIs, and additional equipment.
Map communication flows: Create documentation that details the communication interactions between your OT devices and IT systems. Through this process you will discover key monitoring locations.
Define monitoring priorities: Not all systems are equally critical. Determine which assets and processes require monitoring priority based on their criticality to your operations.
Implement basic monitoring: Begin with fundamental availability and performance checks for your essential systems. You gain instant benefits while developing a complete solution by implementing basic monitoring capabilities.
Expand and refine: Begin with basic coverage and then extend your monitoring scope while tailoring alerts and dashboards using operational insights.
PRTG licensing operates based on sensor numbers which allows you to grant visibility to all necessary users without cost escalation.
PRTG functions as an enhancement tool for SCADA systems instead of acting as their replacement. SCADA systems provide superior process control and visualization capabilities while PRTG specializes in monitoring infrastructure. The ideal setup uses both: Operational processes require SCADA while PRTG monitors infrastructure health.
PRTG maintains security within OT settings using encrypted protocols such as OPC UA and certificate management capabilities. The system tracks certificate expiration dates to avoid communication disruptions from expired certificates. PRTG deployment on isolated networks without internet connectivity is possible when security policies require it.
The user-friendly design of PRTG enables OT staff to use the system without needing advanced IT skills. The map feature enables operators to build visual dashboards which look similar to HMI screens and simplifies their transition. Basic monitoring becomes familiar to most users after several days of implementation.
The increasing convergence of IT and OT systems makes comprehensive monitoring solutions like PRTG essential tools for modern operation environments. Organizations need a unified interface to access SCADA systems and sensors because it has evolved from being convenient to essential for remaining competitive in the market.
PRTG enables full OT monitoring across any environment regardless of its complexity. The PRTG system provides unified visibility and control across food production operations as well as building systems and industrial processes to maintain reliability and efficiency while meeting compliance requirements.
Oh, and if you're ready to unify your IT and OT monitoring, Try PRTG Network Monitor free for 30 days and experience a hassle-free monitoring experience.