Legacy industrial equipment was not designed for modern connectivity, cloud integration, or rising cybersecurity requirements, leaving many manufacturers stuck with multi-vendor hardware of varying ages and security levels, outdated software stacks, and limited access to machine data.
Regulations tighten, and digital service demands grow. Companies must adopt scalable architectures, secure update processes, and hardware‑agnostic strategies to safely extend the life of existing assets and unlock new value from long‑running machine fleets.
Your free assessment includes:
✓ High-level review of the existing industrial (brownfield) environment
✓ Identification of connectivity, integration, and data access challenges
✓ Initial assessment of legacy software and security constraints
✓ High-level recommendations for modernization and secure connectivity
✓ Definition of potential next steps tailored to your setup
Digitalization of existing assets
is not a simple task
Digital services require machine connectivity on the shop floor and to the cloud. Machine data must be collected and processed in real time at the edge and/or transmitted to the cloud as needed. These requirements drive digital applications.
At the same time, cyberattacks on industrial companies increase. The Cyber Resilience Act (CRA) and NIS2 add further requirements. Robust cybersecurity and lifecycle support over 10–20 years are key requirements. They ensure future‑proof, secure digital applications.
They safeguard sensitive data
Hardware and scalability are key decision criteria
When it comes to new applications and functionalities, hardware and scalability are key decision criteria for OEMs. Hardware‑independent solutions enable companies to select the best fit for their machine. Software can be deployed and updated more easily. Centralized platform solutions make this more convenient.
Key challenges to modernized brownfield machines
Lacking access to machine data
Insufficient or unstructured machine data is often the root cause for why new services cannot be implemented. Predictive maintenance, analytics, and digital services require large amounts of data, as real-time collection is essential for processing and decision-making directly at the machine edge. This is often not possible with existing machines that do not have the right access interfaces to handle these requirements.
Integrating inflexible brownfield systems
Many machine builders and OEMs operate heterogeneous system landscapes that have evolved over many years and comprise a wide range of industrial PCs, Linux setups, and software versions. This leads to high service costs, susceptibility to errors, and prevents scaling. Older machines may have more capabilities than can be accessed with their existing control system, so they need to be connected securely within the system.
Modernizing brownfield assets is hindered by outdated software stacks
Legacy software and the lack of secure remote update mechanisms often make it harder to implement digital services in brownfield machinery. Many machine parks feature a mix of modern IIoT technology and older fieldbus systems that cannot easily exchange data across system boundaries, hindering the gathering and processing of machine data required for digital services.
Handling upgrades and maintenance across the whole lifecycle
Long machine lifecycles of up to 20 years require consistent updates, maintainability, and remote support. At the same time, service in the field requires more effort when software versions are not clearly distinguished, or updates need to be distributed manually. For remote updates, a centralized management system and secure remote access to machines in the field with appropriate monitoring, logging, and access control are essential.
What is the solution?
A future‑proof solution combines hardware‑independent architectures, modern software stacks, robust cybersecurity, and structured lifecycle management to support new digital applications, regulatory requirements, and ongoing system growth. With the right foundation, legacy machines can be securely integrated, updated, and expanded without disrupting operations. Start with a free brownfield assessment to identify modernization potential, risks, and next steps for your machinery.
Your free assessment includes:
✓ High-level review of the existing industrial (brownfield) environment
✓ Identification of connectivity, integration, and data access challenges
✓ Initial assessment of legacy software and security constraints
✓ High-level recommendations for modernization and secure connectivity
✓ Definition of potential next steps tailored to your setup
Request a free online assessment
and understand how your existing industrial (brownfield) environment
can be modernized and securely connected, without replacing current systems.
Meet the expert
Miodrag Veselic
Miodrag Veselic is an expert in industrial automation with many years of experience in functional safety, openSAFETY, and the digitalisation of machines and systems. He combines deep technical know-how with market and customer perspectives and has worked in technical expert roles as well as in responsible sales roles at B&R Industrial Automation, and is currently active at TTTECH Industrial.
About us
TTTECH Industrial
TTTECH Industrial is part of the TTTECH Group, a global group of high-tech companies headquartered in Vienna. TTTECH Industrial supports machine builders and OEMs in building software-enabled, networkable, and updatable machines by combining transformative technologies with hands-on experience in critical real-time systems, software, hardware, and safety engineering.
TTTECH Industrial serves the industrial and energy markets with its IIoT platform, Nerve, and customized safe and secure software and hardware engineering solutions.
