Industrial IoT (IIoT)Modbus, OPC-UA & SCADA Integration.
Bespoke Industrial IoT (IIoT) services. Modbus RTU/TCP, OPC-UA industrial protocol gateways, SCADA cloud integration, factory machine condition monitoring, and edge PLC automation.
Modbus & OPC-UA
Legacy PLC Bridge Gateways
SCADA Cloud
Ignition & Wonderware Sync
Vibration FFT
Edge Bearing Fault Diagnostics
ATEX Certified
Explosion-Proof Hardware
Why Industrial IoT
Modbus & OPC-UA protocol bridging. SCADA cloud sync.
Enterprise IIoT engineering combines industrial protocol gateways, SCADA cloud integration, high-frequency vibration FFT diagnostics, and ATEX explosion-proof hardware.
Modbus & OPC-UA Protocol Bridging
Bridging legacy Siemens, Allen-Bradley, and Mitsubishi PLCs to cloud platforms via Modbus RTU/TCP and OPC-UA gateways.
Factory SCADA Cloud Integration
Integrating plant SCADA (Ignition, Wonderware) software with cloud IoT backends for unified multi-site factory visibility.
High-Frequency Vibration FFT Sampling
Sampling 10,000Hz motor vibration data directly at the edge to calculate FFT spectrums for instant bearing fault detection.
ATEX / IECEx Explosion-Proof Certification
Designing intrinsically safe, ATEX-certified hardware enclosures for hazardous oil refineries and chemical plants.
IIoT Capabilities
Modbus gateways, SCADA sync & predictive maintenance.
We deliver full-suite IIoT services covering edge PLC programming, OEE analytics, ATEX hardware design, and WebSockets HMI operator dashboards.
Industrial Protocol Gateway (Modbus / OPC-UA / PROFIBUS)
Developing hardware gateways translating legacy Modbus RTU, RS-485, and OPC-UA tags into JSON MQTT dispatches.
SCADA Platform Integration (Ignition / Wonderware)
Connecting plant SCADA servers with AWS IoT Core and Azure IoT Hub for real-time executive dashboards.
Edge PLC Programming & Node-RED Automation
Writing PLC control logic (Ladder Logic, Structured Text) and deploying Node-RED edge flows on Linux gateways.
High-Frequency Vibration & Thermal FFT Telemetry
Sampling 24-bit ADC vibration sensors to execute on-edge Fast Fourier Transform (FFT) machine diagnostic routines.
Overall Equipment Effectiveness (OEE) Analytics Engine
Calculating real-time Availability, Performance, and Quality metrics for automated manufacturing lines.
Predictive Maintenance & Remaining Useful Life (RUL)
Running Python Scikit-Learn models predicting motor bearing wear and spindle breakdown 14 days before failure.
ATEX / IECEx Intrinsically Safe Hardware Design
Designing explosion-proof ATEX Zone 1/21 certified sensor enclosures for hazardous oil and chemical facilities.
Sub-50ms Industrial WebSockets Monitoring UI
Building live WebSockets operator dashboards displaying real-time 3D plant layouts and machine alarms.
Industry Solutions
Industrial IoT platforms for every commercial sector.
From smart factory machine monitoring to oil & gas telemetry, automotive assembly lines, pharmaceutical cleanrooms, and water treatment, we engineer IIoT.
Smart Factory Machine Condition Monitoring IIoT
Deploying 1,000Hz vibration and motor temperature sensors across 200 CNC milling machines in automated plants.
Oil & Gas Pipeline Remote Pressure & Leak IIoT
Monitoring remote pipeline pressures over ATEX-certified satellite gateways to instantly trigger emergency shutoffs.
Automotive Manufacturing Line OEE & Assembly Tracking
Tracking robotic arm welding cycles, conveyor belt speeds, and calculating real-time line OEE efficiency.
Pharmaceutical Cleanroom Temperature & Humidity IIoT
Monitoring FDA 21 CFR Part 11 compliant temperature, humidity, and particle count sensors in sterile cleanrooms.
Chemical Plant Explosion-Proof ATEX Sensor IIoT
Deploying intrinsically safe gas sensors across chemical distillation towers with automated safety shutdowns.
Water & Wastewater Treatment Plant SCADA IIoT
Connecting water purification SCADA PLCs with cloud analytics to monitor pH levels, turbidity, and pump flow.
Food & Beverage Bottling Line Quality Inspection IIoT
Integrating high-speed optical vision cameras and weight sensors to reject improperly sealed bottles on conveyors.
Commercial Power Plant Generator & Turbine Telemetry
Monitoring 3-phase AC power quality, turbine vibration, and transformer oil temperatures in utility power plants.
Mining Equipment Heavy Machinery Telematics IIoT
Tracking diesel haul truck hydraulic pressures, tire temperatures, and GPS locations in open-pit mines.
Steel Mill Furnace Thermal & Cooling Water Telemetry
Monitoring 1,500°C blast furnace temperatures and cooling water flow rates to prevent catastrophic shell breaches.
Paper & Textile Mill Roller Tension IIoT Systems
Measuring high-speed paper roller tension and web break detectors to minimize raw material waste.
Cold Storage Warehouse Ammonia Leak & Temp IIoT
Deploying ammonia gas leak detectors and freezer temperature sensors with automated emergency ventilation dispatches.
IIoT Feature Modules
Production-ready IIoT feature components.
Complete list of Modbus/OPC-UA bridges, SCADA cloud engines, and Node-RED edge flow runners included.
Modbus RTU/TCP & OPC-UA Protocol Bridge Core
Hardware-to-cloud translator converting legacy PLC registers into JSON MQTT telemetry payloads.
SCADA Cloud Gateway & Ignition Integrator Engine
Bi-directional gateway connecting plant SCADA tags with AWS IoT Core and Azure IoT Hub.
Linux Edge Gateway & Node-RED Flow Runner
Industrial DIN-rail gateway running Node-RED flows and Dockerized edge microservices.
24-Bit ADC Vibration FFT Diagnostic Module
High-frequency ADC sampling engine calculating real-time vibration velocity and acceleration FFTs.
Overall Equipment Effectiveness (OEE) Calculator
Real-time calculation of machine Availability, Performance rate, and Quality output percentages.
Predictive Machine Failure ML Model Executor
On-edge ML execution engine predicting motor bearing remaining useful life (RUL).
ATEX Zone 1/21 Intrinsically Safe Shield
Hardware isolation circuitry complying with ATEX and IECEx explosive environment safety rules.
Sub-50ms WebSockets Plant Monitoring UI
Real-time HMI operator dashboard displaying live machine states, alarm logs, and trend graphs.
Audit Trail & IIoT Machine Command Log Vault
Permanent timestamp logs recording every PLC register write, alarm ack, and operator override.
PostgreSQL TimescaleDB Plant Telemetry Vault
ACID database storage logging billions of industrial time-series metrics with isolated plant schemas.
Single Sign-On (SSO)
Integrating SAML 2.0 and Azure AD for secure corporate industrial plant management console access.
Automated Monthly Industrial Plant ROI Reports
Cron-scheduled dispatches detailing plant OEE improvements, energy consumption, and prevented downtime.
Technology & Tools
Modern IIoT technology stack. High throughput.
We use Modbus RTU/TCP, OPC-UA, Ignition SCADA, Node-RED, Siemens S7, TimescaleDB, and ATEX Hardware.
Industrial Protocols
- Modbus RTU / TCP
- OPC-UA (IEC 62541)
- PROFIBUS / PROFINET
- EtherNet/IP (CIP)
SCADA & Edge Software
- Ignition SCADA by Inductive
- Node-RED Edge Flows
- ThingsBoard PE IIoT
- CODESYS SoftPLC
PLCs & Hardware
- Siemens S7-1200 / S7-1500
- Allen-Bradley ControlLogix
- Schneider Modicon
- Advantech ADAM Gateways
Edge Languages
- Embedded C / C++
- Python (FastAPI / SciPy)
- Go (Golang)
- Structured Text (IEC 61131-3)
Time-Series & Cloud
- TimescaleDB (PostgreSQL)
- AWS IoT SiteWise
- Azure Digital Twins
- InfluxDB Industrial
Safety & Certifications
- ATEX Zone 1/21
- IECEx Explosion-Proof
- SIL 2 / SIL 3 Functional
- ISO 13849 Safety
Security & Quality
Encrypted industrial credentials vault & 100% Modbus register QA.
NDAA NDA compliance, granular operator HMI access controls, and ATEX explosion-proof enclosure verification.
IIoT Security Standards
Encrypted Industrial Gateway Credentials Storage
Protecting plant PLC passwords, Modbus register maps, and cloud MQTT keys with AES-256.
NDAA & SOC 2 Compliant IIoT Operations
Enforcing strict non-disclosure security standards for client plant schematics and OEE manufacturing metrics.
Granular Operator HMI Permission Access
Restricting PLC write commands, motor speed overrides, and alarm clears to certified plant operators.
Immutable Industrial Command Revision Audit Logs
Permanent timestamp logs recording every PLC setpoint change, operator command, and alarm acknowledge.
Isolated OT Air-Gapped Network Sandboxes
Testing IIoT gateways on isolated Operational Technology (OT) test benches before connecting to factory networks.
QA & Ergonomics Verification
100% Modbus / OPC-UA Register Polling QA
Testing gateway polling routines under 500 PLC register load to verify zero communication timeouts.
24-Bit ADC Vibration FFT Calibration QA
Calibrating vibration sensor ADCs against shaker tables to guarantee 100% accurate FFT velocity readings.
ATEX Explosion-Proof Hardware Enclosure QA
Verifying intrinsically safe current limiters and flameproof enclosures comply with ATEX Zone 1 standards.
Sub-50ms HMI Touch Screen Latency QA
Measuring operator button-touch to PLC relay output response to verify sub-50ms real-time control.
E2E Plant Downtime Emergency Shutdown QA
Simulating high-pressure alarms to verify IIoT gateways initiate automated safety shutdowns in under 10ms.
12-Step Lifecycle
Proven Industrial IoT methodology.
From OT plant assessment to gateway selection, vibration PCB design, Node-RED firmware, SCADA cloud pipelines, OEE analytics, HMI dashboards, and Site Acceptance Testing (SAT).
Plant OT Assessment & PLC Audit
Auditing factory PLCs (Siemens, Allen-Bradley), network topologies, Modbus registers, and SCADA architectures.
Industrial Protocol Gateway Specification
Selecting DIN-rail edge gateways and configuring Modbus RTU/TCP or OPC-UA register polling rules.
High-Frequency Vibration Sensor PCB Design
Designing 24-bit ADC vibration and temperature sensor boards with RS-485 Modbus output.
Edge Node-RED & Microservices Firmware
Writing edge gateway software translating PLC tags into JSON MQTT dispatches and running FFT calculations.
SCADA & AWS/Azure Cloud Pipeline Setup
Connecting plant SCADA (Ignition) with AWS IoT Core or Azure IoT Hub for real-time data warehousing.
Real-Time OEE & Predictive ML Model Build
Deploying real-time OEE calculation software and training machine failure prediction models on historical data.
WebSockets Operator HMI Dashboard Build
Designing 3D plant layout operator dashboards displaying live machine states and alarm dispatches.
Factory Site Acceptance Testing (SAT)
Installing hardware in factory, executing 72-hour SAT stress tests, and training plant maintenance technicians.
Industry Domain Focus
Industrial IoT platforms built for your sector.
We build industrial gateways, SCADA pipelines, and OEE analytics tailored to your specific commercial sector.
Enterprise B2B & SaaS
Connecting enterprise equipment, server room environmental sensors, and office energy management systems.
Healthcare & Life Sciences
Monitoring FDA 21 CFR Part 11 compliant temperature, humidity, and particle count sensors in sterile cleanrooms.
FinTech & Financial Services
Deploying tamper-proof IoT smart safes, biometric ATM monitoring, and physical vault intrusion sensors.
Real Estate & PropTech
Monitoring commercial building HVAC power meters, chillers, and boiler room SCADA controllers.
Logistics & Supply Chain
Tracking refrigerated shipping container temperatures, door open events, and GPS routes across international transit.
E-Commerce & Marketplaces
Deploying 1,000Hz vibration and motor temperature sensors across 200 CNC milling machines in automated plants.
Related Services
Explore complementary IoT & embedded services.
FAQ
Industrial IoT FAQs.
Questions we get before kicking off Modbus RTU/TCP, OPC-UA, and SCADA cloud gateway engineering.
- We deploy non-intrusive edge gateways that connect to existing RS-485 Modbus lines or read OPC-UA tags over Ethernet. The gateway acts as a read-only listener, ensuring plant control loops remain completely undisturbed.
Let's build something great
Tell us your IIoT goals.We'll build your Modbus gateways & SCADA cloud sync.
Schedule a free plant IIoT consultation with our senior industrial automation engineers. Receive an OT network architecture review, Modbus gateway plan, and project estimate.