Good practices for communication between IT and OT networks. How to build a secure and modern industrial architecture?

Digitalization of manufacturing plants has made automation systems and IT systems work together more closely than ever before. Machine data flows into MES, ERP, and analytical platforms, while IT systems increasingly need access to industrial devices to monitor their status, security, and compliance with corporate policies.
This creates tremendous opportunities for business growth, but it also introduces an area that requires exceptional caution. Communication between IT and OT networks is one of the most sensitive points within a facility — it is exactly here where vulnerabilities can emerge, leading to cyberattacks or disruptions in production processes.

Why does IT–OT communication require a carefully designed architecture?

OT systems operate in an environment where any unplanned downtime generates real, measurable costs. Failures, communication overloads, or unauthorized PLC-level changes can stop a production line or mislead operators. At the same time, the IT department must be able to monitor security, access logs, and centrally manage the network.

Without a well-designed architecture, the two worlds start interfering with each other. IT updates may unintentionally stop OT devices, and machine-generated traffic can overload the office network. That is why it is essential to design connections so that data flows securely, reliably, and under strict control.

A good practice: architecture with a dedicated DMZ zone

Many modern manufacturing plants use a three-tier architecture that links IT and OT through a DMZ zone. This is a practical compromise between the need for data exchange and the need to protect industrial processes.

In practice, it works like this: the OT network — which includes PLC controllers, HMI panels, sensors, and communication gateways — is completely isolated from the office network. Between them sits a DMZ zone: a logically and physically separated network space where intermediary servers and systems requiring access from both sides are located. This is typically where the MES system operates, bridging machine data with higher-level systems such as ERP or analytical tools.

Communication takes place through two firewalls: the first separates IT from the DMZ, and the second protects the DMZ from the OT side. Thanks to this, OT devices — such as Weintek HMI panels — communicate only with the intermediary layer, not directly with the IT department. This prevents situations where office traffic, updates, or unauthorized actions could affect production processes.

This setup allows full control over data flow — administrators can define how machine data enters MES and which data can be transferred further. This ensures not only security, but also stability and predictability of the entire infrastructure.

Why trusted devices and software matter

Even the best network architecture will not function properly if OT devices fail to ensure stability and adequate security. For this reason, more and more plants rely on established manufacturers such as Weintek, whose devices are designed specifically for industrial environments.

HMI panels, IoT gateways, and communication controllers of this class come with durability certifications, stable industrial protocols, and predictable product lifecycles with long-term technical support. This is critical because cheap substitutes often behave unpredictably, may introduce security gaps, or generate communication issues.

Combined with a robust MES system, this makes it possible to build an environment that not only meets technical requirements but is also resistant to cyberthreats.

OmniMES — a MES system built with cybersecurity in mind

Within such a complex architecture, the MES system must fully comply with IT–OT communication principles. OmniMES was designed specifically to operate in segmented network environments, including DMZ setups, firewall-protected zones, and isolated industrial subnets.

OmniMES supports encrypted transmission, ensuring that data transferred between machines, IoT modules, and the server is protected from interception or tampering. Each user has precisely assigned permissions, minimizing the risk of unauthorized actions. The system also integrates with industrial devices, ensuring stable operation even in high-reliability, high-security environments.

This makes OmniMES not only a source of production insights but also a solution aligned with modern industrial cybersecurity policies.

Secure IT–OT communication starts with good practices

Implementing an MES system that acts as a bridge between IT and OT requires proper architecture, trusted hardware, and cybersecurity-compliant solutions. The combination of a DMZ zone, properly configured firewalls, stable IoT devices, and the OmniMES system ensures secure data exchange without the risk of disrupting production processes.

If your company plans to organize its IT–OT communication or is considering implementing a modern, cyber-secure MES system, OmniMES provides stability and protection at every stage.

Fill out the contact form and learn how to implement a secure IT–OT architecture in your facility.