Digitalization is advancing steadily in the manufacturing industry. To work more efficiently, faster, and with fewer errors, manufacturing companies are connecting machines and systems across the production chain. From machines to delivery vans, production lines to inventory systems, these components are increasingly interconnected via the Industrial Internet of Things (IIoT).

This digital transformation is giving rise to the "smart factory"—a production environment where humans, machines, software, and automation seamlessly collaborate. Here, real-time production data drives process organization. By collecting and analyzing this data, smart factories can respond quickly to market changes, helping businesses stay ahead of the competition.

In a smart factory, service technicians can identify defective parts within seconds using augmented reality, while employees monitor and adjust product quality directly from streaming data. Self-driving robots transport components between workstations, and machines use predictive maintenance to alert teams to potential wear and tear before breakdowns occur.

However, the increase in data sources and intensified data exchange in smart factories presents new challenges. By 2026, the data circulating globally within the manufacturing industry is expected to be valued at over $9 billion. While this creates immense opportunities, it also underscores the growing need for robust data security. In this article, we’ll explore the key security challenges manufacturing companies face and how to build a secure IT infrastructure to support your smart factory.

Security and the Manufacturing Industry: The Challenges

Building a safe, smart, and digitized factory comes with significant security challenges. A cyber incident that halts production—even briefly—can have far-reaching consequences.

“Take a bottle producer, for example. If production lines stop for just 15 minutes, the costs are significant. Operators must restart the lines, reset processes, and recalibrate ingredient mixes. This results in extra time, effort, and money,” explains Erwin uit de Bos, solutions architect at Digital Realty.

Here are the main cybersecurity challenges faced by modern manufacturing companies:

Ransomware and cyber attacks

The manufacturing sector is one of the most targeted by cybercriminals due to its high IoT connectivity. Ransomware attacks—where systems, files, or networks are encrypted, and a ransom is demanded—are especially common. Vulnerabilities in secure data exchange frameworks leave companies susceptible to ransomware, data leaks, or theft, leading to costly disruptions, fines, damage claims, and reputational harm.

Distant security providers

Many leading security providers are based far from Europe, in locations like the U.S. or Israel. These providers often have access to your IT infrastructure and data, but their geographical distance can limit transparency and insight into their operations.

Connectivity risks

Reliable connectivity is crucial for smart factories. Many organizations aim to avoid the public internet due to its inherent risks. “The public internet is like a forest after sunset—you never know what’s lurking in the dark,” says Uwe Pferr, solutions architect at Digital Realty. The expanding digital economy increases potential attack surfaces, making visibility and control over connectivity critical.

Unpatched IoT sensors

The growth of IoT sensors in smart factories brings added risk. Many sensors are left unpatched or retain default settings, making them vulnerable to attack. For example, hackers can exploit default passwords on smart security cameras, gaining unauthorized access to settings and data.

How to Create a Secure IT Infrastructure for Manufacturing

To ensure data integrity and operational resilience, manufacturing companies must build robust IT infrastructures. Here are the key pillars:

Firewalls, encryption, and antivirus software

These fundamental security measures protect against external threats like malware and hackers, forming the first line of defense.

Effective network design

A strong network design ensures high performance and security. Incorporating measures like zero-trust architecture and identity/access management enhances protection.

Private global connectivity

Using private connections instead of the public internet minimizes risks. For example, IoT device sensors sending data to a central storage environment remain secure, as private networks block unauthorized access.

Data-centric architecture solutions

Redundant, professionally managed data centers provide continuous availability and disaster protection. Features like 24/7 monitoring and biometric access controls further secure critical systems.

Zero-trust security model

Adopting a "never trust, always verify" approach strengthens security. All users and devices must continuously prove their trustworthiness, creating a robust foundation for IT infrastructure.

Backup and disaster recovery

A solid backup strategy ensures rapid recovery in case of an incident. For example, beverage manufacturers with reliable backups can resume operations faster, reducing downtime and losses.

Continuous monitoring

Advanced monitoring tools detect and resolve potential threats quickly, keeping the IT environment secure.

Policies and Procedures for Security

Clear policies and consistent procedures help maintain IT infrastructure security. These include:

Access rules: Define who can access data and what actions (viewing, editing, approving) they can take.
Incident management: Establish clear protocols for responding to and mitigating security incidents.
Timely updates: Ensure all systems are regularly updated with the latest patches to close vulnerabilities.

How Digital Realty Supports Manufacturing Companies

Digital Realty connects companies and data through a full suite of data center, colocation, and connectivity solutions. Our PlatformDIGITAL® solution is specifically designed to adapt to evolving demands in data, control, and networks.

PlatformDIGITAL® features include:

Network Hub: Securely connects global network traffic without relying on the public internet, enabling rapid scaling.
Control Hub: Enhances infrastructure management and security through globally distributed control points.
Data Hub: Brings critical data infrastructure closer to users, networks, and clouds for improved performance.
ServiceFabric® Connect: Enables tailored virtual connections based on business needs, ensuring flexibility and security.
24/7 monitoring and support: With 300 highly secure data centers across six continents, we provide extensive security expertise and robust infrastructure.

“Our foundation is so strong that even if one or two pillars fail, the entire structure remains intact,” say Erwin and Uwe.

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