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Industrial Technology Blueprint

IT/OT segmentation & plant network designs that eliminate manufacturing downtime.

Seven network architecture diagrams, starting with IT/OT network segmentation, that we deploy in production plants. The network topologies, protocols and configurations we deploy in production plants — each with the vulnerability it removes, the specification that removes it, and the number it's held to.

A/01 Layer-3 VLANsA/02 Multi-WANA/03 SSD CAD cacheA/04 HA virtualisationA/05 3-tier DMZA/06 Encrypted meshA/07 3-2-1 DR
Architecture 01

Layer-3 switch hierarchy & VLAN segmentation

Vulnerability · flat networkAn ad-hoc, flat 192.168.1.0/24 subnet, daisy-chained unmanaged switches, broadcast storms from CNC controllers and lateral malware movement from office to shop floor.

A Layer-3 core managed switch with 802.1Q trunking enforces strict isolation across a 7-VLAN matrix. Inter-VLAN traffic is default-deny; the few permitted flows are explicit ACLs, and OT transfers move through unidirectional jump proxies.

VLAN 10 Mgmt20 Office/ERP30 CAD 10GbE jumbo40 OT air-gapped50 DMZ60 CCTV/biometrics70 Guest
Try the interactive VLAN matrix
SYS_REF · ARCH_01802.1Q
Layer-3 core switch with 802.1Q trunk fanning out to seven isolated VLANs, inter-VLAN default denyCORE SWITCH L3802.1Q trunkVLAN 10MgmtVLAN 20Office/ERPVLAN 30CAD 10GbEVLAN 40OT · CNCVLAN 50DMZVLAN 60IoT/CCTVVLAN 70Guest
Architecture 02

Zero-downtime multi-WAN gateway groups & traffic shaping

Vulnerability · single ISPOne point of failure halts billing, ERP and truck gates.

Dual- or triple-WAN gateway groups on the firewall that fits the site: Tier 1 leased line, Tier 2 fibre broadband, Tier 3 4G/5G cellular. Failover triggers automatically on packet loss above 15% or latency above 80 ms. Policy-based routing and QoS preserve the leased line's committed rate for ERP, CAD sync and VoIP while bulk traffic rides broadband.

<3 sfailover recovery time
SYS_REF · ARCH_02Gateway group
Multi-WAN gateway group: leased line, fibre broadband and 4G/5G feeding a multi-WAN firewall that routes ERP, CAD, VoIP and bulk trafficTIER 1Leased lineGuaranteed CIR / SLASTANDBYTIER 2Fibre broadbandFailover targetSTANDBYTIER 34G / 5G cellularLast-resort backupSTANDBYFW-GATEWAYMulti-WANfirewallgateway groupERP / accountsPBR · priorityvia T1CAD syncPBR · priorityvia T1VoIPPBR · priorityvia T1Bulk / updatesQoS · shapedvia T1
Architecture 03

CAD/CAM storage acceleration with Smart Fetch

Storage bottleneckMechanical NAS arrays choke on random-read IOPS during large assembly loads, freezing workstations for 5–10 minutes.

Smart Fetch is our performance design: network storage tiering with RAID 6 behind a mirrored flash tier that serves the active working set, and metadata pinning that keeps 3D assembly directory trees in flash. It increases productivity by more than 60%. A 10GbE backbone with multichannel file sharing lifts throughput from 110 MB/s to 1,000+ MB/s.

90%+Smart Fetch design efficiency increase
60%+Productivity increase
SYS_REF · ARCH_03Tiered storage
CAD/CAM storage acceleration with Smart Fetch: a mirrored flash tier in front of a RAID 6 disk tier, increasing efficiency by 90%,, served over a 10GbE backbone to engineering workstationsCAD WS 01CAD WS 02CAD WS 03CAD WS 04CAD WS 0510GbE switch backbone · multichannel file sharing · jumbo frames (VLAN 30)NETWORK STORAGE · METADATA PINNED TO SSDSmart Fetch · hot flash tierMirrored flash · absorbs random IOPS and directory metadata90%HDDHDDHDDHDDHDDHDDCold tier · RAID 6 spinning disks
Architecture 04

High-availability virtualisation, licence-light

Threat · licensing shockHypervisor licensing shock and no high-availability clustering for critical servers.

A type-1 hypervisor cluster with replicated storage. Remote-desktop servers run on paravirtualised disk controllers with dedicated I/O threads and 10G virtual NICs. A deduplicating backup server adds client-side encryption and incremental VM backups that finish in under 90 seconds.

30+concurrent remote-desktop users per cluster
SYS_REF · ARCH_04PVE HA
High-availability virtualisation cluster of three hosts running a remote-desktop server farm, protected by a deduplicating backup serverRemote-desktop server farm5 session hosts · 30+ concurrent plant usersPVE_NODE_01HypervisorReplicated storageParavirtual disk I/O10G virtual NICPVE_NODE_02HypervisorReplicated storageParavirtual disk I/O10G virtual NICPVE_NODE_03HypervisorReplicated storageParavirtual disk I/O10G virtual NICHA cluster · quorumDeduplicating backup serverchunk dedup · client-side encryption
Architecture 05

Air-gapped OT security & 3-tier DMZ vendor portal

Exposure · vendor accessSuppliers need a portal; that portal must never become a path to CAD shares or the ERP database.

An edge firewall terminates the WAN and VPN and absorbs ingress. A DMZ firewall hosts the web vendor portal behind a Layer-7 reverse proxy and web application firewall. A core firewall protects Active Directory, the ERP and CAD repositories.

100%vendor portal DMZ isolation
SYS_REF · ARCH_053-TIER_DMZ
Three-tier defence-in-depth: an edge firewall, a DMZ firewall hosting the vendor portal behind a reverse proxy and web application firewall, and a core firewall protecting Active Directory, ERP and CAD repositoriesINTERNETTIER 1 · EDGEEdge firewall— WAN termination— VPN endpoints— DDoS / ingressTIER 2 · DMZDMZ firewall— Web vendor portal— Layer-7 reverse proxy— Web app firewallTIER 3 · CORECore firewse— Active Directory— Windows ERP— CAD repositoriesVENDORS NEVER REACH CORE SHARES
Architecture 06

Hardware-accelerated encrypted multi-site mesh

Vulnerability · fragile linksConsumer VPNs and open port-forwarding between sites create critical security gaps.

Encrypted site-to-site tunnels (AES-256-GCM with dead-peer detection) connect plants. Remote engineers connect through an encrypted VPN with handshakes under 50 ms and seamless roaming, only from approved devices and with Active Directory sign-in. RDP and file shares are closed to the internet, and MFA is mandatory.

<50 msVPN handshake latency
SYS_REF · ARCH_06Mesh
Multi-site mesh: HQ and plant joined by an encrypted site-to-site tunnel with AES-256-GCM; remote users connect over an encrypted VPN from approved devices with directory sign-in; zero public port forwardingSite-to-site tunnel · AES-256-GCMRemote VPNApproved devices onlyMAIN HQHQ firewallPLANT SITEPlant firewallREMOTE USERApproved device · AD · MFARDP / FILE SHARES CLOSED TO INTERNETZERO PORT FORWARDING
Architecture 07

Ransomware-resistant 3-2-1 disaster recovery pipeline

Threat · ransomwareBackups on the same network as production get encrypted with production.

Hourly snapshots locked by WORM retention. Nightly encrypted replication to an independent backup server at another plant. Weekly encrypted copies to immutable cloud storage on AWS, Azure or Google Cloud. Application-aware image backups protect virtualised databases.

3-2-1copies · media · offsite, with immutability
SYS_REF · ARCH_07DR pipeline
Ransomware-resistant 3-2-1 pipeline: hourly immutable local snapshots, nightly encrypted replication to an offsite plant, weekly encrypted copies to immutable cloud storageTIER 1 · LOCALImmutable snapshotsHourly snapshotsWORM retention locksHOURLYTIER 2 · OFFSITE PLANTEncrypted replicationNightly, encrypted tunnelIndependent backup serverNIGHTLYTIER 3 · CLOUD VAULTImmutable cloud vaultWeekly encrypted copyImmutable archiveWEEKLYAPPLICATION-AWARE IMAGE BACKUPS · DEDUPLICATION
Reference

Technical architecture & protocol matrix.

01 · Network02 · Storage03 · Compute04 · Security05 · Backup
Layer-3 switchingTiered network storageHA virtualisation cluster3-tier DMZDeduplicated VM backup
802.1Q VLANsSSD RAID 1 cacheType-1 hypervisorUTM where it fitsApplication-aware image backup
Multi-WAN firewallSmart Fetch · 90% efficiencyParavirtual I/OIntrusion preventionImmutable snapshots
Gateway groups · PBR10GbE fabricRemote-desktop farmEncrypted VPN · device + AD authImmutable cloud vault
Implementation

The 30-day engineering roadmap.

A phased rollout with minimal operational disruption.

01
Week 1

Engineering audit

Topology audit, cable tracing, Layer-2/Layer-3 discovery.

02
Week 2

Edge security

Multi-WAN firewalls, gateway groups, 3-tier DMZ.

03
Week 3

Storage optimisation

Smart Fetch storage design, 10GbE uplinks, virtualisation cluster initialisation.

04
Week 4

Final integration

VLAN segmentation, backup activation, 24/7 monitoring.

Schedule an on-site engineering audit.

Week 1 of the roadmap — and useful on its own, whatever you decide next.

Schedule the audit See it in production