Industrial Network Planning
Custom-fit PROFINET and mixed-protocol networks engineered for OT/IIT/IIoT environments.
Powerful networks as the basis for industrial digitalization
Whether you’re expanding a line, adding new machines, or connecting separate plants, your industrial network is the backbone of production. It has to move process data reliably, across multiple network levels (OT/IIT/IT), without introducing risk or downtime.
And every network is different.
Hardware, topology, protocols, and local conditions mean that “off-the-shelf” designs rarely fit.
InduSol America supports OEMs, system integrators, and plant operators with industrial network planning and validation – from PROFINET network design and load planning, to integrating existing PROFIBUS, EtherNet/IP, and mixed OT environments. We plan new networks, analyze existing ones, and give you a clear, documented path to a stable, expandable infrastructure.
Talk to an Industrial Network Specialist Network Architecture and Digitalization
Core components of our network planning approach
New systems (greenfield / major expansions)
- Concept and topology design for PROFINET and mixed-protocol networks (PROnetplan V2)
- Selection and dimensioning of switches, cabling, and infrastructure components
- Network load and multicast planning for real-time traffic and future IIoT use cases
- Documentation (layouts, IP plans, VLAN/segmentation concept) for hand-off to OEM/SI teams
Existing systems (brownfield plants)
- As-is network capture (topology, devices, load, weak points)
- Identification of bottlenecks, EMC and equipotential bonding issues, and single points of failure
- Modernization roadmap: low-risk steps to move from “working” to stable and expandable
Testing & optimization
- On-site measurements of PROFINET/Industrial Ethernet load and quality
- Verification of cycle times, jitter, and bandwidth reserves
- Recommendations for parameter changes, segmentation, and hardware upgrades
Commissioning support
- Pre-commissioning checks and acceptance measurements
- On-site or remote support during start-up and ramp-up
- Documentation for audit records
Measuring & validation tools
- Use of InduSol measurement tools (PROFINET-INspektor®, PB-Q ONE, EMCheck, etc.) during the project
- Optional hand-over of monitoring concepts so your team can keep tracking performance after go-live
- Convenient network planning via drag-and-drop
- Intuitive network load pre-planning
- Planning of copper, fibre-optic and WLAN-based network connections
- Creation of communication relationships between components
Independent network planning for industry & engineering
Until a few years ago, industrial plant networks, in particular, operated separately from one another (referred to as homogeneous networks). However, with increasing connectivity and modern monitoring solutions, maintaining this separation has become the exception rather than the norm. Consequently, most industrial networks today are heterogeneous or convergent networks. The interconnection of these modern industrial networks presents new challenges for planners and operators.
Changing criteria for networks and components
The complexity of industrial networks and their requirements is already evident in the initial planning stages, including the design of cable routes, industrial switches, and other network components. Gone are the days when network components from the same manufacturer as the used PLC could be simply installed. In the future, the selection of the appropriate network infrastructure components will primarily depend on the specific requirements of the individual segments as well as the overall network.
Specific network planning instead of costly oversizing
Besides planning highly available industrial networks, the economic efficiency of these networks plays a crucial role in every phase. While generous oversizing may save time during network planning, the subsequent costs of materials and additional maintenance efforts often negate any initial savings. Therefore, our specialization lies in adapting industrial networks to meet the exact on-site requirements.
Advantages of network planning (per user group)
Mechanical / plant engineering
(electrical construction)Creating stable, cost-efficient networks
Challenges
- Designing modern, digitalized systems
- High cost pressure (competitors + customers)
Advantages of network planning
- Simplified commissioning (costs ↓)
- Lower service costs (costs ↓) already during warranty
- Stronger network infrastructure (mostly price neutral)
Plant operator
(maintenance / availability)Networks as basis for maximum availability
Challenges
- Long-term profitability
- Maximize plant availability
Advantages of network planning
- Basis for high system availability (more fault reserves, fewer error sources)
- Reduced maintenance costs (plannable, targeted measures)
- Lower or no remodeling costs
Plant operator
(IT / networking)High-performance networking from OT to IT
Challenges
- Linking single networks (interference-free)
- Coordination of processes & components
Advantages of network planning
- Interference-free integration of different networks
- Avoid infrastructure-related bottlenecks
- Lower or no remodeling costs
Your road to an optimized network
Plant projects usually include a basic planning of the individual plant and the network it contains. (ACTUAL)
The plant concept and the connected networks are checked by us. The total required network performance is calculated. (TARGET)
Based on the ACTUAL and TARGET status, we check the existing network concept and the network components used for their suitability.
Based on all relevant requirements, network structure and components, such as switches, are coordinated with each other.
In a final step, our experts accompany the implementation in an advisory role or provide technical measurement support during the approval process and commissioning.
Need help planning your industrial network?
Talk with our engineering team about PROFINET/PROFIBUS/OT–IT integration, segmentation, and network load planning.
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