INDUSTRIAL COMMUNICATIONS:
KEY TO AUTOMATION

by marketing on 5 de May de 2025

WHAT ARE INDUSTRIAL COMMUNICATIONS AND WHY ARE THEY KEY TO AUTOMATION?

In the age of automation and digital transformation, industrial communications have become the nervous system of any production environment. From the coordination of sensors to the integration of complex systems in production lines, the efficient and secure transmission of data is essential to ensure agile, accurate and scalable processes.

These networks not only enable communication between devices and machines, but also connect different levels of an industrial plant, facilitating communication between heterogeneous networks. In sectors where quality control and traceability are essential - such as dynamic weighing or automated inspection - having a robust communication infrastructure makes all the difference.

At Varpe we explain what industrial communications are, how they work, what types exist and why they are key to meeting the challenges of Industry 4.0. If your goal is to optimise the performance of your processes, read on. 

INTER-NETWORK COMMUNICATION IN INDUSTRIAL ENVIRONMENTS

In a modern industrial environment, it is not enough for devices to communicate within a single network: it is essential that different industrial networks can exchange information seamlessly, securely and in real time. This is known as inter-network communication, a key pillar in achieving connected, scalable production systems that are compatible with the Industry 4.0 philosophy.

THE ROLE OF GATEWAYS AND PROTOCOL CONVERTERS

To achieve this interoperability, industrial gateways or protocol converters are used. These devices act as translators between networks using different communication languages.

For example, a gateway can allow a PLC operating on EtherNet/IP to communicate seamlessly with field devices using CANopen. In addition, many of these converters integrate filtering, monitoring and diagnostic functions, making them strategic elements in maintaining network reliability. 

INTEROPERABILITY STANDARDS IN INDUSTRIAL NETWORKS

There are numerous standards designed to facilitate interoperability between devices. Some of the most relevant are: 

OPC UA (Open Platform Unified Communications Architecture)

It facilitates the secure and structured exchange of data between devices and systems, regardless of vendor. 

TSN (Time-Sensitive Networking)

Extends Ethernet to ensure synchronisation and deterministic transmission, essential for critical processes. 

MQTT o AMQP

Increasingly used in environments where industrial systems are connected to cloud platforms or IIoT (Industrial Internet of Things) solutions. 
Implementing these standards not only improves compatibility between networks, but also builds an infrastructure ready for future technology growth, with less reliance on customised integrations and more operational flexibility. 

MAIN TYPES OF INDUSTRIAL NETWORKS

Networking type Speed Real time Wiring Ideal for:
Profibus Medium Medium Yes Robust environments, simple sensors
Profinet High High Yes Process automation
EtherCAT Very high Very high Yes Robotics, high synchronisation
EthernetCAT High Medium Yes General control, IT integration
Zigbee/loRaWAN Low Low No Long range monitoring
Industrial Wi-fi High Miedium No Mobile systems, AGVs, warehouses

PRACTICAL APPLICATIONS OF INDUSTRIAL COMMUNICATIONS

Industrial communications play an essential role in multiple processes within industrial automation, enabling not only the control and monitoring of devices, but also full systems integration that improves efficiency, reduces errors and optimises traceability.

Below, we highlight some key practical applications, especially relevant in sectors where quality control and dynamic weighing are critical: 

Dynamic weighing on production lines

In systems such as checkweighers, industrial communications allow:

- Direct connection with PLCs and SCADA systems.

- Automatic recording of weighing data in real time.

- Activation of alarms or automatic rejection if the products do not comply with the defined standards.

- Full traceability through protocols such as Profinet, EtherNet/IP or Modbus TCP.

This guarantees a continuous flow of information between the machine and the central system, which translates into greater reliability in the inspection and control of the final product. 

Integration with vision and inspection systems

When using X-ray inspection or machine vision systems, industrial communications allow:

- Send images and reports to central servers.

- Interconnection with ERP or MES software for real-time analysis.

- Synchronisation with actuators to reject non-conforming products.

This level of integration ensures that every stage of the process is connected and able to make autonomous decisions based on data. 

Coordination of automated multi-equipment lines

In environments where several machines - such as labellers, packaging machines, metal detectors and weighers - work together, industrial communications enable:

- Seamless synchronisation between equipment.

- Automatic parameter adjustments according to batch or product type.

- Reduced downtime due to communication errors.

Thanks to these connections, more efficient, flexible lines can be achieved with less human intervention. 

BENEFITS OF GOOD INTER-NETWORK COMMUNICATION

A well-implemented industrial architecture with inter-network communication not only enables the flow of data, but completely transforms the way production processes are managed. Effective connectivity between systems, machines and platforms improves operational efficiency on multiple levels.  

Reduction of downtime

When networks are properly integrated, systems can communicate in real time, detect errors quickly and make automatic decisions to correct deviations. This translates into:

- Fewer unplanned outages.

- Immediate remote fault diagnosis.

- More effective preventive maintenance thanks to reliable data.

In machinery such as inspection and weighing systems, this allows the line to be kept in continuous operation, even in the event of minor incidents.             

Improving quality control

Seamless communication between sensors, vision systems, metal detectors and monitoring software enables:

- Real-time quality control.

- Automatic registration of each evaluated product.

- Implementation of automated rejection criteria.

This is especially relevant in sectors where regulations require full traceability, such as the food or pharmaceutical industry.           

Increased security and traceability

Connecting all the elements of the process under standardised protocols facilitates:

- Full traceability from raw material input to final product output.

- Data security through the use of robust industrial protocols (OPC UA, MQTT).

- Rapid identification of the source of errors or deviations in production.

In addition, a well-designed infrastructure allows the application of multi-layered security rules (industrial firewalls, segmented networks), reducing the risk of unauthorised access. 
The combination of these benefits not only improves the technical performance of operations, but also brings direct business value: cost reduction, regulatory compliance, customer satisfaction and demand flexibility. 

THE ROLE OF INDUSTRIAL COMMUNICATIONS IN INDUSTRY 4.0

The advent of Industry 4.0 has transformed the traditional concept of automation, demanding smarter, more flexible and secure networks. In this new paradigm, industrial communications are the essential support for interconnecting all the elements of the production ecosystem: from sensors and actuators to cloud platforms and artificial intelligence systems. 

Full interconnectivity: from sensor to server

In a 4.0 environment, information must flow constantly between all levels of production:

- Field level: sensors, dynamic scales, metal detectors, inspection cameras.

- Control level: PLCs, HMI, programmable controllers.

- Supervision level: SCADA, MES and ERP systems.

- Cloud level: advanced analytics, predictive maintenance, global traceability.

All this is possible thanks to intelligent industrial networks, capable of handling large volumes of data, prioritising critical traffic and guaranteeing minimum response times.             

Data driven communication and decision making

New industrial solutions must not only communicate input and output signals, but also exchange complex, structured data that feeds optimisation, AI or machine learning algorithms.

For example, Varpe's weighing and inspection systems can be integrated with cloud platforms to:

- Analyse production trends.

- Detect deviations by AI.

- Issue predictive alerts before errors occur.

This not only improves efficiency, but empowers real-time decision making, from the operator to strategic management.           

Scalability and adaptability

Another key aspect of the connected industry is adaptability. Thanks to standardised protocols such as OPC UA or MQTT, it is possible to add new devices, modify lines or reconfigure processes without having to redo the entire network infrastructure.

This scalability allows companies to grow without compromising system reliability and facilitates the incorporation of new technologies such as digital twins or industrial blockchain.                   

HOW TO CHOOSE THE RIGHT INDUSTRIAL NETWORK

Choosing the right industrial network is a critical decision that directly influences the performance, scalability and total cost of ownership of any automation system. There is no one-size-fits-all network: the selection must be made based on the specific needs of the production environment.  

KEY FACTORS TO TAKE INTO ACCOUNT

When evaluating different industrial networks, the following aspects should be considered:

- Transmission speed: High frequency processes such as dynamic weighing or robotics require high speed networks such as EtherCAT or Profinet.

- Response time (latency): If precise synchronisation is required, protocols with deterministic communication should be chosen.

- Compatibility with existing devices: check which protocols are supported by existing PLCs, sensors and SCADA systems.

- Scalability: the network should allow new equipment or lines to be added without redesigning the entire architecture.

- Environmental conditions: in harsh or vibrating environments, a robust protocol such as CANopen or a low-power wireless network may be more suitable.

- Implementation cost: includes cabling, configurations, necessary gateways and software licenses.

TYPICAL USE CASES

Industrial necessity Recomended network Justification
Dynamic weighing with automatic rejection Profinet/EtherNet/IP high speed and precise syncronizing 
Integration of legacy equipment Modbus/CANopen Compatibility and low cost
Collaborative robotics EtherCAT Very low latency deterministic communication
Monitoring of distributed processes LoRaWAN/Zigbee Long distance wireless connectivity
Factories with an Industry 4.0 vision OPC UA/MQTT Scalability and connection to cloud platforms
The chosen network should be seen as a strategic investment, as it will affect the entire data infrastructure of the company. Having the right technical advice is key to making sound and sustainable decisions. 

THE FUTURE OF INDUSTRIAL COMMUNICATIONS: TOWARDS SMARTER AUTOMATION

As industry moves towards increasingly automated, connected and data-driven production environments, investing in industrial communication technologies is no longer an option, but a necessity. Only those organisations able to ensure seamless integration between machines, people and systems will be able to respond nimbly to the challenges of today's market: customisation, regulation, energy efficiency and sustainability.

At Varpe, we understand that each process has unique needs. That is why our solutions not only stand out for their precision in weighing or inspection, but also for their ability to integrate into modern industrial networks, compatible with the main protocols on the market. We work to make industrial connectivity an enabler, not a barrier. 
If you are looking for a weighing or inspection solution that fits your communication infrastructure, or need advice on how to integrate your equipment into a smart industrial network, contact our technical team.
We help you take the next step towards more connected, efficient and future-proof automation. 

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