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Hybrid DCS evolution - bridging legacy and digital control
Business Brief
|BusinessBrief October/November 2025
Today's industrial automation continues to evolve at a blistering speed which means traditional Distributed Control Systems (DCS) have to keep up to ensure continuous integration into modern, digital infrastructure.
DCS' very nature is to multitask, therefore, controlling and coordinating complex processes within industrial settings. But what if the growth of industrial automation becomes an insurmountable challenge?
DCS' multitasking can only go that far - it needs to modernise in order to juggle, if you will, protocol compatibility, legacy infrastructure, cybersecurity and human factors. The solution, a hybrid approach which allows DCS to evolve as the industrial landscape grows.
In essence, a hybrid DCS combines traditional industrial automation technologies with modern digital tools like cloud connectivity, edge computing and Ethernet-based protocols, to manage and optimise complex industrial processes. It allows legacy systems to coexist with newer technologies, improving flexibility, visibility and operational efficiency without full system replacement.
Challenges abound
But in order to realise a world - or rather, an industrial world - built on hybrid DCS, it's important to be realistic about the challenges ahead.
Key challenges faced:
Protocol complexity and latency risk
Integrating legacy fieldbus protocols like Foundation Fieldbus, PROFIBUS, and Modbus with modern Ethernet-based standards such as EtherNet/IP and PROFINET introduces latency through gateway solutions. In time-sensitive environments like chemical processing, even a 10–15 millisecond delay can jeopardise control loops and compromise product integrity.
Legacy infrastructure
Longstanding systems continue to deliver dependable performance and reflect years of process refinement. Wholesale replacement poses significant risks, particularly in safety-critical sectors. Digital twins offer a simulation bridge but depend on detailed documentation, often missing in older setups.
Cybersecurity
This story is from the BusinessBrief October/November 2025 edition of Business Brief.
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