Industrial Switches vs. Routers: How to Combine Them for a Reliable and Secure IIoT Network

Industrial networks are becoming increasingly connected.

Manufacturing equipment, sensors, controllers, monitoring systems, cameras, machines, and other industrial devices need to communicate reliably with one another while also connecting to remote locations, cloud platforms, and centralized management systems.

Building this type of environment requires more than simply connecting devices to the internet.

Two important networking components are industrial switches and industrial routers. Although they perform different functions, they work together to create the communication foundation needed for many Industrial Internet of Things (IIoT) environments.

An industrial switch primarily manages communication between devices within a local network, while an industrial router connects that local network to other networks, remote locations, or the internet.

When properly selected and configured, these technologies can help organizations build networks that are reliable, scalable, manageable, and secure.

At Cyber Shield Security, we believe that understanding how these components work together is essential when designing a connected industrial environment.

What Is an Industrial Switch?

An industrial switch connects multiple devices within a local network and allows them to exchange data.

In an industrial environment, a switch may connect devices such as:

• Industrial computers

• PLCs

• Sensors

• Controllers

• IP cameras

• Access control systems

• Monitoring equipment

• Other network-enabled machines

Unlike basic consumer networking equipment, industrial-grade switches are designed for environments where temperature, vibration, electrical interference, and other conditions may place additional demands on networking hardware.

Depending on the network's requirements, businesses can choose between different types of switches.

Unmanaged Switches

Unmanaged switches are generally designed for simpler network environments.

They typically require minimal configuration and can provide straightforward plug-and-play connectivity.

Managed Switches

Managed switches provide greater control over the network.

Depending on the model, they can support features such as:

• Network monitoring

• VLAN configuration

• SNMP management

• Traffic control

• Troubleshooting

• Performance monitoring

Managed switches are particularly useful when organizations need greater visibility and control over industrial network traffic.

Industrial-Grade Switches

Industrial switches are designed specifically for demanding industrial environments.

They generally emphasize:

• Reliability

• Stability

• Environmental resistance

• Network availability

• Industrial connectivity requirements

Choosing the appropriate switch depends on the environment, number of devices, network architecture, and operational requirements.

What Is an Industrial Router?

While switches primarily handle communication within a local network, routers are responsible for moving traffic between different networks.

An industrial router can connect an industrial LAN to:

• Corporate networks

• Remote facilities

• Cloud platforms

• The internet

• Other geographic locations

This makes routers particularly important for organizations that need remote monitoring, centralized management, or communication between multiple facilities.

Industrial routers can also provide security and network management capabilities that help control how information moves between networks.

Industrial Switches and Routers Serve Different Purposes

A simple way to understand their roles is:

Industrial Switch → Connects devices within the local network

Industrial Router → Connects the local network to other networks

For example, imagine a manufacturing facility containing multiple machines, sensors, and monitoring devices.

The industrial switch can connect those devices within the facility.

The industrial router can then provide a controlled connection from that industrial network to a remote monitoring center or cloud platform.

Together, they create a communication path from the equipment to the systems responsible for monitoring and managing it.

Step 1: Determine Your Network Requirements

Before purchasing networking equipment, start with the actual requirements of the environment.

Consider questions such as:

• How many devices need to connect?

• Where are the devices located?

• How much data will they transmit?

• How quickly does information need to move?

• What type of network topology will be used?

• Are remote locations involved?

• Does the environment require wireless connectivity?

• What level of network redundancy is necessary?

• What security requirements must be met?

These considerations help determine the appropriate number of switch ports, network capacity, interfaces, and other hardware specifications.

Choosing equipment first and designing the network afterward can result in unnecessary costs or an infrastructure that cannot support future expansion.

Step 2: Design the Industrial Network in Layers

A structured network architecture can make an industrial environment easier to manage and expand.

A layered design may include:

Access Layer

This is where industrial devices connect to the network.

Switches at this level may connect:

• Sensors

• Controllers

• Machines

• Cameras

• PLCs

• Other field devices

Aggregation Layer

The aggregation layer brings together traffic from multiple access switches.

It can help organize network traffic and simplify management.

Core or Edge Layer

Routers and other higher-level networking equipment can handle communication between the industrial network and external networks.

This may include connections to:

• Corporate IT networks

• Cloud services

• Remote facilities

• Central monitoring systems

• The internet

Logical layering can make a network easier to troubleshoot and expand.

Step 3: Select the Right Industrial Router

Industrial routers come in different configurations.

Wired Routers

Wired routers are appropriate when a stable physical network connection is available.

They can provide reliable communication between industrial networks and external systems.

Wireless Routers

Wireless industrial routers can provide connectivity for environments where physical cabling isn't practical or where mobile devices and equipment require wireless access.

Wireless deployment requires careful consideration of:

• Coverage

• Interference

• Authentication

• Encryption

• Network security

Industrial-Grade Routers

Industrial routers are designed for demanding environments and may provide stronger environmental protection, connectivity options, and reliability than standard consumer networking equipment.

Important Router Features to Consider

When evaluating industrial routers, several capabilities can be particularly important.

WAN Connectivity

The router should support the connectivity method required by the facility.

Depending on the environment, this may include:

• Fiber

• Cellular connectivity

• Wired broadband

• Other WAN technologies

VPN Support

VPN technology can provide encrypted communication between locations and enable secure remote connectivity.

This can be particularly useful when industrial systems need to communicate with remote offices, technicians, or centralized monitoring environments.

Routing Capabilities

Routing requirements can vary depending on network complexity.

Static routing may be appropriate for simpler environments, while dynamic routing protocols can support more complex network structures.

The appropriate configuration depends on the organization's network design.

Step 4: Plan IP Addresses Carefully

IP address planning may seem like a small detail, but poor network planning can create major problems later.

A properly designed network should consider:

• IP address ranges

• Subnet masks

• Default gateways

• Network segmentation

• Device addressing

• Future expansion

Good planning helps prevent address conflicts and makes troubleshooting easier.

It also makes it easier to understand how different sections of the network communicate with one another.

Step 5: Configure Routing Policies

Once the network has been designed, routing policies can determine how traffic moves

between different networks.

Depending on business requirements, administrators may configure:

• Routing priorities

• Traffic policies

• Load balancing

• Network paths

• Access restrictions

The objective is to ensure that important traffic reaches its destination efficiently while unnecessary or unauthorized communication is controlled.

Step 6: Build Redundancy Into Critical Networks

Industrial environments often depend on continuous network availability.

A networking failure can interrupt:

• Production

• Monitoring

• Automation

• Security systems

• Remote access

• Data collection

For critical applications, redundancy can help reduce the impact of a single equipment failure.

Possible approaches include:

• Dual switches

• Dual routers

• Switch stacking

• Redundant network paths

• Backup connectivity

If the primary networking device fails, a properly designed redundant system can allow another device or network path to take over.

The exact redundancy strategy should be based on the operational importance of the system and the acceptable level of downtime.

Step 7: Use Switches and Routers Together for Better Security

Connecting industrial equipment to a network also introduces cybersecurity considerations.

Industrial environments should not simply connect every device to the same unrestricted network.

One useful strategy is network segmentation.

Managed switches can use VLANs to separate different categories of traffic.

For example, an organization could logically separate:

• Production equipment

• Security cameras

• Building systems

• Administrative devices

• Guest access

• Monitoring systems

Segmentation can help limit unnecessary communication between systems and reduce the potential impact of a compromised device.

Use Router Security Controls

Routers can also provide important security controls.

Depending on the equipment, organizations may configure:

• Firewall rules

• Access control lists

• VPN connections

• Network restrictions

• Traffic policies

These controls can help determine what traffic is allowed to enter or leave the industrial network.

The goal is not simply to connect systems.

The goal is to connect them in a controlled and secure manner.

How Switches and Routers Work Together

Consider a simplified manufacturing environment.

A factory has:

• Production machines

• Sensors

• PLCs

• IP cameras

• Monitoring computers

The industrial switches connect those devices within the facility.

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The switches organize and forward local network traffic.

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The router connects the industrial network to an external network.

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A secure connection allows authorized data to reach a remote monitoring platform.

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Security controls determine which traffic is permitted.

This creates a structured network where local communication and external communication are handled according to their respective roles.

Why Configuration Consistency Matters

Industrial switches and routers don't operate independently.

Their configurations need to work together.

Important network settings can include:

• IP addresses

• Subnet masks

• Default gateways

• VLAN configuration

• Routing policies

• Security rules

Configuration errors can result in problems such as:

• Devices being unable to communicate

• Incorrect routing

• Network congestion

• Security gaps

• Difficult troubleshooting

Proper documentation and testing are therefore essential when deploying or modifying industrial networks.

Plan for Future Expansion

Industrial networks rarely remain the same forever.

Businesses may eventually add:

• More machines

• Additional sensors

• New production lines

• More cameras

• Remote facilities

• Cloud-connected systems

• Additional monitoring technologies

Network infrastructure should therefore have enough capacity to accommodate future growth.

Planning for expansion from the beginning can reduce the need for expensive redesigns later.

Cyber Shield Security: Helping Businesses Build Connected and Protected Networks

Modern industrial environments require more than connectivity.

They require visibility, reliability, security, and resilience.

At Cyber Shield Security, we understand that networking and security are increasingly interconnected.

Our technology solutions can support businesses with:

Network Security

Help protect business and industrial networks through appropriate security controls and network architecture.

Security Cameras

Deploy intelligent video surveillance systems for facilities, warehouses, manufacturing environments, and other commercial properties.

Access Control

Help organizations control and monitor access to restricted areas.

Alarm Systems

Provide additional protection against unauthorized entry and security incidents.

Remote Monitoring

Maintain visibility into connected security and technology systems even when personnel are away from the facility.

Network and Infrastructure Support

Help businesses maintain reliable connectivity across their technology environment.

Cybersecurity Solutions

Support businesses in identifying and addressing potential cybersecurity risks across connected systems.

Professional Installation and Support

Proper planning, configuration, installation, and ongoing support can help ensure that networking and security technologies work together effectively.

Build a Stronger Industrial Network With the Right Combination

Industrial switches and routers have different responsibilities, but they work best when they are designed as part of the same network strategy.

Switches connect devices within the local industrial environment.

Routers connect those networks to other networks and external resources.

When combined with proper IP planning, network segmentation, redundancy, routing policies, security controls, and professional configuration, they can provide the foundation for a more reliable and secure IIoT environment.

The key is to avoid treating networking equipment as isolated hardware.

Instead, look at the entire environment:

Devices → Switches → Network Segmentation → Router → Secure External Connection → Monitoring and Management

A well-designed network can improve communication, simplify management, support future expansion, and help protect critical industrial systems.

Cyber Shield Security can help businesses evaluate their networking and security requirements and develop solutions designed around their facility, technology, and operational needs.

Build your industrial network for today's requirements—and prepare it for tomorrow's connected world.