TL;DR
Your plant runs on mixed systems. Reliability depends on how well they share data. A clear communication strategy keeps operations smooth and upgrades predictable.
As plants grow, they naturally accumulate a mix of automation technologies. A core process may run on Siemens. Packaging or utilities rely on Rockwell. A new OEM skid arrives with Beckhoff controls. Older systems stay in place because they work—and work reliably. Add a SCADA refresh, and suddenly you have an ecosystem built over years of expansion and modernization.
This isn’t a problem in itself. It’s simply the reality of how facilities evolve. But it does mean your operations depend on many behind-the-scenes data exchanges between systems not originally designed to speak the same way.
When those exchanges are clean, operations feel stable and predictable. When they’re not, you see inconsistent alarms, mismatched values, slower troubleshooting, and operators losing confidence in what they see.
Your plant functions because its systems communicate. Your plant flourishes when that communication is reliable.
The real challenge isn’t the variety of platforms—it’s making sure they can work together without adding friction to daily operations.
What Cross-Platform Communication Really Means
Cross-platform communication is simply how different systems share information. Siemens, Rockwell, Beckhoff, OEM skids, and legacy PLCs all generate data—but they don’t organize that data the same way or update it at the same pace.
To keep operations running smoothly, these systems need a reliable way to exchange information with one another—and with SCADA or HMI. When that structure is in place, operators see one unified picture. When it’s not, you get frozen screens, unpredictable alarms, mismatched values, or displays that don’t reflect what’s actually happening.
And the consequences aren’t just technical. Poor communication leads to more troubleshooting hours, slower response times, avoidable downtime, and lost revenue—all because systems aren’t aligned on how they share and interpret data.
Why the Matters:
Cross-platform communication is a business issue as much as a technical one. It directly impacts uptime, efficiency, and operational clarity.
Three Essentials That Keep Mixed Systems Running Smoothly
Modern plants rely on a blend of platforms, but reliability depends on how well those systems work together. These three essentials determine whether operations feel unified—or fragmented.
1. Shared Ways of Communicating
Different platforms use different methods for structuring and transmitting information. To work together, they need a compatible communication path—a way to exchange data that every system involved can understand.
How plants get there:
- Use communication standards (like OPC UA) supported across vendors
- Apply interface or bridging solutions when older or proprietary equipment needs help communicating
- Plan communication paths early, before equipment is installed
Key Takeaway:
Shared data pathways reduce blind spots and keep information moving reliably.
2. Data That Looks the Same Across the Plant
Even if systems communicate, they may not describe or prioritize information the same way. Operators feel this immediately—messy screens, inconsistent alarms, or values that don’t match.
How plants get there:
- Establish a United Naming Convention for equipment and tags
- Standardize alarm prioritization
- Use a supervisory layer to unify data structures
Key Takeaway:
Consistent data isn’t just about names—it’s about aligning how different systems structure and prioritize information. When that’s unified, operators get a clearer picture and can respond with confidence.
3. A Network Ready for Growth
Modern control systems rely on networks moving thousands of updates per second. If the network isn’t designed for industrial traffic—or for secure communication—well-engineered systems can still appear slow or unreliable.
How plants get there:
- Use managed switches that prioritize industrial traffic
- Segment networks so critical systems have clean, reliable pathways
- Design for future load—not just today’s needs
- Support secure communication, including certificate management where required
Key Takeaway:
A healthy network ensures data reaches the people who need it—securely and without delay.
Use a Supervisory “Translation Layer” to Bring Your Systems Together
A supervisory translation layer sits between your PLCs and operator-facing tools. It’s not “just SCADA”—it’s the architectural layer that makes mixed systems feel unified.
What it does:
- Collects data from multiple platforms
- Normalizes tags, naming, and alarms
- Smooths timing and update-rate differences
- Provides one trusted source of truth for screens and dashboards
- Shields operators from PLC-level changes during upgrades
How plants implement it:
- OPC UA as a universal standard
- Protocol gateways for legacy or proprietary systems
- SCADA or a data hub configured as the organizing layer
Key Takeaway:
A translation layer is a design choice—not a product. It helps mixed systems function as one clear, reliable ecosystem.
Common Cross-Platform Risks and Simple Ways to Avoid Them
Even well-run plants feel the strain when different systems don’t communicate cleanly. The issues aren’t usually dramatic—but they are persistent, costly, and avoidable with the right structure in place.
Here’s a streamlined look at the most common risks leaders see and how to get ahead of them:
Cross-Platform Risk Overview
What You See
New or legacy equipment doesn’t talk cleanly; values don’t match
How to Prevent It
Use shared standards (like OPC US) or add gateways to bridge platforms
What You See
Screens don’t match; alarms behave differently across areas
How to Prevent It
Normalize tags/alarms through a supervisory layer
What You See
Slow HMIs, intermittent updates, unreliable data
How to Prevent It
Use managed switches, segment networks, and size for future growth
Bottom line:
Cross-platform issues aren’t technical mysteries—they’re predictable challenges that strong communication planning can prevent.
Leadership Checklist: Before Adding Any New System
- Will it communicate cleanly with our existing systems?
- Will operators see consistent data and alarms?
- Can our network handle the new traffic?
- Do we need a supervisory layer to keep things organized?
- Will this addition simplify –or complicate– future upgrades?
Modern Plants Thrive on Connection
Mixed-vendor systems are the norm. What matters most isn’t which platforms you choose—but how well they work together. Clean, consistent communication supports uptime, clarity, and modernization.
A strong communication strategy gives your team one reliable view of the process and reduces the surprises that come with piecemeal upgrades.
That’s where Pigler Automation can help. Through AUDITIQ™, we assess your communication landscape, identify hidden risks, and build a practical, right-sized plan for more reliable, connected operations.
Your plant doesn’t need to be uniform—it needs to be connected.
And we’re here to help you get there.
See What's Really Going on Inside Your Control System
AUDITIQ™ gives you a clear picture of risks, priorities, and improvement paths — without committing to a full project. If you’re planning upgrades or troubleshooting recurring issues, this is the fastest way to get clarity.
See What’s Really Going On Inside Your Control System
AUDITIQ™ gives you a clear picture of risks, priorities, and improvement paths — without committing to a full project. If you’re planning upgrades or troubleshooting recurring issues, this is the fastest way to get clarity.
