Most Important Connectivity Trends in Industry

[Erkan Teskancan]

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Industrial networks form the backbone of control systems, enabling communication between controllers, sensors, actuators, and enterprise systems. In this era of accelerating digital transformation, the need for robust, scalable, and intelligent connectivity solutions is growing.

According to the 2025 report published by HMS Networks, Ethernet-based industrial networks account for 76% of new node installations, an increase of 5% compared to 2024. On the other hand, the share of older fieldbus technologies has dropped to 17%, while wireless systems remain at 7%. This trend reveals a preference for flexible and scalable Ethernet solutions with deterministic communication protocols that support real-time control and data exchange.

Although not dominant, wireless technologies play a significant role, especially in applications requiring mobility and used in hard-to-reach areas, such as automated guided vehicles (AGVs) and wireless sensors. 5G technology stands out with its potential to solve latency and bandwidth issues, but there are problems to overcome, such as infrastructure complexity and industrial environment challenges. While 4G technology is still common for batch production and automation, 5G is gaining more importance in future strategic plans.

### The Rise of Hyperconnectivity
While the integration of information technology (IT) and operational technology (OT) has been a trend in recent years, this trend has become more pronounced in 2025. Industrial networks are evolving to support hyperconnectivity, where devices and subsystems are interconnected across multi-layered automation levels. In batch production facilities, the demand for real-time event-based data is increasing. ISA-95 and ISA-88 standards play a key role in the contextual hierarchical structuring of this event data.

Hyperconnectivity offers manufacturers advantages such as continuous production process monitoring, instant data transmission between systems and machines, and scalable integration of different devices and protocols. Ethernet-APL (Advanced Physical Layer), time-sensitive networks (TSN), and edge-based platforms facilitate this integration, enabling deterministic communication and centralized data management.

### The Impact of Open Protocols and Data Fabrics
Interoperability and standardization support the development of open protocols and communication standards like OPC UA and MQTT. These protocols enable seamless integration of devices and systems from different vendors. This increases flexibility while reducing integration costs and fostering innovation. At the same time, the standard structure offered by OPC UA and MQTT prevents data silos and reduces the risk of errors.

Since batch manufacturers use complex control systems, OPC UA and MQTT are critical for collecting data and transmitting it to the enterprise layer. Batch production generates a lot of data; collecting, contextualizing, and visualizing this data can be challenging. A rising trend in this area is industrial data fabrics, which bring together data from multiple sources into a single space, enabling analysis in the cloud. This approach allows for advanced analytical applications for predictive maintenance, quality control, and operational optimization.

### Ongoing Challenges and Opportunities in Industrial Connectivity
With increasing levels of connectivity, risks also rise. OT cybersecurity has become a fundamental requirement for industrial networks. As remote access and cloud integration become more widespread, systems and data must be protected against both internal and external threats. Network segmentation, zero-trust architectures, and compliance with standards like ISA/IEC 62443 are among the key strategies.

Nevertheless, some challenges persist:

• Integrating existing systems, especially in older facilities, remains a major obstacle. Not all legacy systems support OPC UA and MQTT protocols.
• The implementation costs of advanced technologies like TSN and 5G are high.
• Ensuring the reliability and redundancy of data sources for analyses at the enterprise layer can be difficult; hot failover is critical for uninterrupted data flow.

These challenges also create opportunities:

• System designs are now focusing on modular and scalable solutions.
• Creating reliable data in batch production is crucial; redundant data sources and hot failover systems prevent data gaps, ensuring continuous data flow.

### Future Perspective
Industrial control systems will evolve towards increased integration of information technology and operational technology, widespread adoption of edge-to-cloud architectures for real-time analysis, implementation of industrial data fabrics, and robust OT cybersecurity strategies.