The convergence between OT and IT is redesigning safety and efficiency in industrial processes. Understand the risks and benefits of this integration.
The rapid evolution of integration between Operational Technology and IT
The industry is experiencing a new era of digital transformation. The convergence between OT (operational technology) and IT (information technology) represents one of these profound changes, capable of impacting not only the productivity and control of industrial processes, but also the way companies deal with cybersecurity, physical devices and their critical infrastructures.
OT is operational technology that refers to the systems that monitor and control equipment, machines and infrastructure in industrial environments. These systems, traditionally isolated, are increasingly connected to IT networks to ensure more intelligent, integrated and real-time operations. According to a Gartner report, by 2026, 75% of industrial organizations will have implemented integrated OT-IT architectures to accelerate automation and cyber resilience initiatives.
Why is the integration between Operational Technology and IT so important?
Historically, operational technology systems operated independently of corporate IT networks. While OT focused on stability, predictability, and physical security, IT focused on data, communication, and information.
With digital transformation and the growing demand for efficiency and automation, these two worlds have become interconnected. The convergence of IT and OT enables more responsive, data-driven operations with greater predictive analytics capabilities. In addition, this integration allows decisions made at the strategic level to be quickly translated into operational actions. The result is an operation that is more aligned with business objectives.
This integration is also driven by the popularization of the Industrial Internet of Things (IIoT), which connects sensors, actuators, and field devices to information systems. This interconnected ecosystem improves control and provides valuable insights, but it also expands the cyberattack surface.
Direct benefits of OT + IT integration
- Real-time monitoring: managers have immediate access to production, failure and performance data, which allows for agile and evidence-based responses.
- Operational efficiency: integration allows for process optimization, waste reduction and better results with fewer resources.
- Rapid responses: incidents can be detected and dealt with much more quickly, minimizing risks and losses.
- Failure prediction: with historical data analysis and machine learning, systems can predict maintenance before shutdowns, reducing corrective maintenance costs.
- Data-driven decision-making: integrated data increases the company’s operational and strategic visibility.
Also read: Data Revolution: Power BI, AI and Analytics Redefining Business Success
Challenges and risks of convergence
Despite the benefits, the integration between OT and IT also presents significant challenges, especially when it comes to the security of operational technology. OT systems can be vulnerable to attacks when exposed to conventional IT networks. In addition, many OT networks still use legacy systems, with a low level of cyber protection and without frequent updates.
According to the ISA (International Society of Automation), around 60% of industrial environments still operate with outdated or discontinued industrial control systems (ICS). This makes them easy targets for attacks such as ransomware, sabotage and intrusions into critical networks.
The implementation of robust OT security measures is essential. This includes industrial firewall, network segmentation, strong authentication, continuous monitoring and, of course, staff training. OT security must be considered from the design of networks, with strategies such as “defense in depth” and the use of security zones segmented by function.
Another recurring challenge is organizational culture. OT and IT professionals often speak “different languages,” have different priorities, and take different approaches to problem-solving. Fostering collaboration between these areas is crucial to successful convergence.
Practical cases: Natural Gas and the Automotive Industry
In natural gas distribution, OT systems such as smart meters and connected sensors are essential for measuring, controlling pressure, detecting leaks and real-time billing. Integrating these solutions into the IT infrastructure allows the collected data to feed billing systems, ERPs and BI dashboards with greater agility and accuracy.
T4i Solutions, for example, developed UniGás, a specialized management platform for natural gas distributors, which integrates measurement, billing, trading and logistics modules. The system has already billed more than 40 billion m³ of gas, supporting the digital transformation of companies in the sector with security and scalability.
In the automotive industry, the convergence of OT and IT makes it possible to track the entire production chain, identify bottlenecks, anticipate mechanical failures and adapt production in real time based on logistical and market variables. Industrial robots connected to IT networks allow automatic adjustments to the production line according to demand, reducing losses and increasing operational flexibility.
Best practices for safe and efficient integration
- Map your networks: Identify where OT and IT systems are located and how they communicate. Create a detailed inventory of physical and digital assets.
- Implement layered security: Protect your devices physically, logically, and digitally. Use industrial firewalls, intrusion detection systems (IDS), and multifactor authentication.
- Update your OT systems: Whenever possible, replace legacy systems with up-to-date solutions with active security support.
- Establish clear incident response protocols: OT also needs a cyber contingency plan aligned with the business continuity plan.
- Promote collaboration between IT and operations teams: Convergence is not just technological, it is also cultural. Conduct cross-training and create joint committees.
- Use scalable and interoperable solutions: Avoid closed tools. Opt for platforms that offer flexibility, integration via APIs, and support for widely accepted industry protocols.
- Conduct regular audits: assess vulnerabilities in industrial control systems and OT networks. Fix flaws before they are exploited.
- Adopt the principle of least privilege: restrict access to systems to only what is necessary for each employee’s role.
More information about security: What is OT security?
Conclusion
The convergence between operational technology and information technology is inevitable in a market that demands efficiency, security and real-time decision-making. OT and IT can — and should — coexist in an integrated, secure and strategic manner.
Companies that anticipate this trend ensure not only competitiveness, but also resilience in the face of cyber and operational risks. T4i Solutions is prepared to support this movement, offering robust solutions that combine efficiency, security and a vision of the future.
Because integrating OT and IT is much more than connecting systems. It is building a new level of operational intelligence, prepared for the challenges of an increasingly digital and interconnected market.