Another IT (Information Technology) vs. OT (Operational Technology) post? Yes, but bear with us - this one is in self-defense. We’re called OTee, but when we discuss our SaaS platform for virtual PLC (Programmable Logic Controller) with customers and automation engineers in detail, they will hear us speaking a lot about data, communication frameworks, and virtualization or virtual PLC - terms that have more of an information technology flavor to it than an operational one.
“So, what are you then? OT or IT?”
In this blog, we’ll skip the sometimes tiring IT vs. OT debates and explore what convergence really means in practice. We’ll focus on how the Virtual PLC transforms the way we think about control logic and hardware. Along the way, we’ll bring a real-world example: a geothermal plant using external price forecasts to optimize its pump operations.
By exploring this case and the bigger architectural shift behind it, we’ll show how IT and OT convergence, powered by Virtual PLC, is more than just a buzzword. It’s a real step toward creating automation environments that are more flexible, open, and effective.
No IT/OT overlap, let’s call it IT and OT convergence!
Where do we begin? Let’s get some definitions and disclaimers in place, first. If we define IT’s focus as data and information processing, and OT’s main concern as controlling physical processes and machines, then it is probably fair to say that we have moved past the “gap” between those two domains over the past decade or so.
In fact, there’s now a growing overlap! Boundaries and responsibilities are blurring, yes, sometimes causing confusion, but this should be seen as a positive sign: IT and OT are finally collaborating!
So, rather than referring to this as mere “overlap,” let’s call it what it is: IT and OT convergence.
Both domains are approaching one another, and this shift lays the groundwork for smarter, integrated automation systems.
Key Drivers Behind IT and OT Convergence
What is pushing IT and OT closer together?
One major driver is the realization of the untapped potential within operational data. From basic digitalization to advanced analytics and optimization, businesses are beginning to see the immense value of shop floor data reaching the IT layers of the automation stack, integrating seamlessly into MES (Manufacturing Execution Systems) and ERP (Enterprise Resource Planning) systems.
At the same time, there’s growing potential for the PLC and machine layers to process and react to a far wider range of data sources, whether from top-level systems or really any data stream on the internet which the operations team finds relevant to drive automated control.
The conversation around IT and OT convergence isn’t new. We’ve come a long way from the days when OT environments were sealed off and “hands-off” for IT teams. Today, production data flows much more freely up the automation stack, playing a vital role in business decision-making.
However, the next step, where data from external sources trickles down the automation stack to drive control logic, remains underdeveloped.
2 Key Challenges in IT and OT Convergence
Cybersecurity
One of the biggest concerns in achieving true bi-directional communication across the automation stack is cybersecurity. Traditionally, OT systems were designed to operate within isolated environments, disconnected from external networks. While applying protective measures (like firewalls and segmentation) around these domains is a common workaround, it doesn’t address the core vulnerability.
Hardware dependency
Another significant challenge for the OT domain is its hardware dependency. This issue manifests in two key ways:
Diverse Hardware Landscape: OT environments often blend the latest edge technology with equipment that’s 30+ years old. This diversity makes it difficult for IT systems to operate reliably and securely across such a heterogeneous infrastructure.
Proprietary PLC Constraints: Perhaps the most fundamental technology in industrial automation, the PLC, is trapped inside a proprietary physical box. Automation vendors use this as a gatekeeper of operational data and to trap customers into their particular product palette; as a result, the innovation space for customers is limited and hardware dependencies hardened.
IT and OT Convergence Current state: Hopes vs. Reality!
The story often goes like this: IT companies see an opportunity to replicate their successful information management practices in the operational technology (OT) world. Initially, there’s excitement. But fast-forward two years, and reality sets in, the complexities of industrial applications hit hard. Another two years pass, and the company either fades away or releases another gateway plus cloud analytics product, bypassing as much of the OT jungle as possible.
It’s understandable, and sometimes it works. However, as an industry, we have reached the limits of how many more point-to-point connections our system architectures can handle.
Is partnership enough?
Companies partner up on projects across domains, hoping to get a better grip on these complexities and buy-in from a cultural perspective. But increasing projects in size and number of contributors doesn’t exactly seem to be the silver bullet in achieving IT and OT convergence either.
Although initiatives like Open Process Automation have made valuable strides in fostering openness, inclusivity, and collaboration across multiple industry domains, the journey toward fully integrating modern IT concepts into traditional OT environments remains complex. A presentation shared at a VMware Explore event highlighted the significant learning curve involved in embracing these emerging technologies, and still reads a bit like IT trying to impose its ways onto OT:
“Most of the people [...] didn't even know what Kubernetes was, let alone what a container was. There was a ton of enablement [...] and it was a massive shift in their thinking to be able to support this.” Source: VMware Explore Video Library
This ongoing effort has required years of investment—both in resources and in education—and reflects the scale and dedication needed before large-scale, industry-wide operational deployments can be realized.
Time to Overcome IT and OT Convergence Challenges with Virtual PLC from Within
These examples highlight a crucial point: IT providers alone will struggle to bring fundamental change to the automation world. Partnering up with OT companies is an honorable approach, but seems to inflate project size at the cost of speed, acceptance, and adoption.
At OTee, we believe that the convergence of these two domains needs to be driven from within the OT space itself. To rethink data frameworks and system architecture in ways that bring real change, we need to address the foundation of the automation stack. This is hardcore OT, but we’ll need all the tools and proven concepts that our IT friends have developed over the past few years.
Key Elements to Drive Convergence with Virtual PLC
VirtualizationTo make the Virtual PLC a reality, we must decouple control logic from dedicated hardware. This removes reliance on proprietary physical devices, offering flexibility, scalability, and adaptability.
Decentralized Data FrameworksWe need resilient, decentralized frameworks for handling structured data around the Virtual PLC layer. This ensures that applications connect via a single interface, eliminating the need for additional point-to-point connections that strain system architecture.
Granular Cybersecurity and Zero TrustTo ensure safe and secure convergence, we need built-in zero-trust mechanisms within the automation stack. Granular cybersecurity measures protect against threats, enabling secure, bidirectional communication between IT and OT environments.
By addressing these core areas, the Virtual PLC becomes a powerful enabler of IT and OT convergence, simplifying architectures, enhancing security, and unlocking innovation.
To dive deeper into these topics, you can also take a look at these blogs: How Do Virtual PLCs Untangle Spaghetti Architecture in Operational Technology? and How a Virtual PLC Solves Your 3 Major Automation Problems.
Real Industry Case Study
Let’s look at a real example from one of our customers: a company operating a geothermal heat plant with a heat storage facility designed to account for seasonal effects.
The goal was straightforward: they wanted to integrate a price forecasting service so their PLC could automatically optimize pump operation logic based on forecasted power prices. However, their system integrator rejected this request due to common IT and OT concerns—specifically, the risk of letting external data flow through the internet and directly influence automated control processes. In other words, it was seen as too much IT infringing on OT.
By adopting the OTee IIoT Platform, the operator overcame this challenge. The solution now allows them to consume price forecasts through a simple REST API into OTee’s pub-sub data framework. This data is then securely passed down to the Virtual PLC.
Key benefits include:
Security: Protection at the device, user, and application levels ensures secure data flow.
Vendor-Agnostic Hardware: The Virtual PLC runs on off-the-shelf computing hardware, eliminating vendor lock-in.
Operational Efficiency: The plant now optimizes pump operations for immediate cost savings.
Future-Proof Architecture: The facility has taken a significant step toward an architecture where legacy systems and new elements can be integrated seamlessly into the pub-sub framework, all through a single interface and at the customer’s preferred pace.
What OTee Brings to the Table
At OTee, we do our part in the movement towards a more open and innovative ecosystem in the automation industry: Virtual PLC based on open, international standards lets customers decouple control logic from any particular vendor’s hardware, putting technology at the center of their operations rather than brands or products. Open data frameworks allow operational data to flow freely through the stack and be securely protected through built-in zero-trust cybersecurity.
So, back to the original question: What are we?
We’re virtualizing one of the most fundamental automation layers: The PLC layer. As the name suggests, we think of ourselves very much as an OT company. But we also strongly believe that IT has a lot to bring to the table - our team composition reflects that, and we’re approaching every opportunity to improve the OT world with all the tools and procedures available to us, regardless of whether they’re labeled one or the other.
What’s the Next Step?
The challenges of IT and OT convergence are real, but they’re solvable. It’s time to stop patching over the divide and start transforming your automation stack from the inside out with Virtual PLC.
Book a Demo: No forms to fill out, just pick a time that works for you, and we’ll discuss how Virtual PLC can help with your IT and OT convergence challenges. No commitments, just useful insights.
Start for Free: Try the OTee IIoT platform yourself, at no cost.
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