Legacy equipment creates major obstacles for IT-OT integration because end users struggle to replace older machines due to cost and specialization constraints. Early collaboration between IT, OT, engineering, and OEMs, combined with hybrid solutions and strategic upgrades, can help overcome these compatibility challenges.
- Legacy equipment acts as isolated islands preventing seamless data exchange between older and modern systems in manufacturing operations.
- End users cite cost constraints and machine specialization as primary reasons for keeping legacy systems rather than upgrading.
- One case study showed that eliminating 80% of legacy equipment through strategic upgrades aligned operations with modern IT-OT standards and improved compatibility.
- OEMs can support integration short-term by offering hybrid solutions enabling older PLCs to communicate with modern systems.
- Long-term success requires early collaboration between IT, OT, engineering, and OEMs to design future-proof machinery with built-in connectivity.
Effective IT-OT integration for end users requires early collaboration between IT, OT, engineering, and OEMs to avoid costly delays and compatibility issues. However, one challenge that stands in the way is figuring out how to handle legacy equipment.
That’s according to PMMI Business Intelligence’s “Performance Optimization: Insights for Packaging Line Readiness,” a report that brings together key issues, industry insights, and recommendations from roundtable discussions and panels featured at the 2025 Top to Top Summit from February 23–25. The summit serves as a platform for OEMs and CPGs to exchange perspectives, address shared challenges, and collaborate on practical solutions.
Most participants were from the food industry (61%). Pharmaceuticals, another notable sector, represented 7% of participation.
End users experience difficulties in eliminating legacy equipment, whether due to cost constraints or the specialized nature of certain machines, the Business Intelligence team finds.
One panelist, an expert in engineering and manufacturing excellence, admitted to having to keep some legacy systems, referring to them as “islands” isolated from newer technologies. Dealing with legacy equipment can mean replacing it or finding solutions that minimize downtime and cost.
Another panelist, an expert in IT from a large CPG, discussed an experience starting a successful digital transformation four to five years back, investing heavily in equipment upgrades to more compatible future-proof solutions. This included outfitting the entire operation, from the plant floor and OT layer to the IT layer, with new technology. The upgrade eliminated 80% of legacy equipment and aligned with modern IT-OT standards.
In the short term, OEMs can support IT-OT integration by offering hybrid solutions that enable older programmable logic controllers (PLCs) and OT networks to exchange data with modern systems. Longer term, end users upgrading to more compatible equipment can future-proof operations and mitigate challenges. Users want OEMs to develop machinery with built-in connectivity, which reduces reliance on traditional computers and ensures seamless integration.
SOURCE: PMMI Business Intelligence: 2025 Performance Optimization: Insights for Packaging Line Readiness
For more insights from PMMI’s Business Intelligence team, find reports, including “2025 Beverage Industry Packaging Trends” and “2025 Aftermarket Parts & Services” at pmmi.org/business-intelligence.
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