Use Case
Protecting Production Automation Systems from
Cross-Line Exposure
Industry: USE CASE | FOOD & BEVERAGE
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Protecting Production Automation Systems Where Packaging and Food-Safety-Critical Systems Meet
A beverage bottling and canning plant found malware on a packaging-line HMI and discovered during the investigation that the packaging network had a direct path to the pasteurization and CIP systems responsible for food-safety-critical temperature holds.
The malware itself was contained quickly. The bigger challenge was proving that it had never reached the systems responsible for keeping the product safe.
Shieldworkz confirmed that the infection never reached the pasteurization or CIP systems, then rebuilt the network so future incidents could not get as close to food-safety-critical process controls.
Value proposition: Confirm whether an infection has reached process-critical systems, separate food-safety-critical controls from general packaging equipment, continuously monitor cross-segment activity, strengthen patch planning, and maintain documentation that can demonstrate system integrity without disrupting production.
Production Automation Security Challenges
Production environments depend on automation systems across mixing, pasteurization, filling, and packaging. When these systems share network infrastructure without effective isolation, an incident affecting one area can create a path toward process-critical controls.
Flat Production Network
Mixing, pasteurization, filling, and packaging automation shared a single network with no isolation between lines.
Food-Safety-Critical Systems Exposed
CIP and pasteurization temperature controls were located on the same network segment as general packaging and labeling equipment.
Unpatched Packaging HMIs
Several packaging-line HMIs ran unsupported software, with no patch plan because the production line could not easily stop to test updates.
No Containment Plan
When the infection was discovered, there was no fast way to confirm that it had not reached process-critical controls.
HACCP Documentation Pressure
A compromised process-control system could force a product hold, and the plant had no quick way to prove system integrity.
Understanding the OT Risk Landscape
Production facilities rely on interconnected automation systems to manage processes across mixing, pasteurization, filling, and packaging.
The challenge is not simply whether systems are documented separately. The actual network architecture must prevent incidents from moving between general production equipment and food-safety-critical process controls.
When packaging and labeling systems share a network path with pasteurization and CIP controls, an incident affecting a packaging-line HMI can create exposure beyond the original system.
Unsupported HMIs and the lack of a structured patch process can increase operational and cybersecurity risk. At the same time, limited visibility can make it difficult to quickly determine whether malware or other threats have moved laterally across the production environment.
Shieldworkz addresses this by combining passive asset discovery, malware containment and verification, network segmentation, OT vulnerability assessment, patch scheduling governance, continuous monitoring, and incident response readiness into a coordinated OT security program.
Common Cyber and Operational Risks Affecting Production Systems
Malware infections on packaging-line HMIs with potential paths toward process-critical controls
Flat production networks with no isolation between mixing, pasteurization, filling, and packaging
Pasteurization and CIP temperature controls sharing network infrastructure with packaging and labeling equipment
Unsupported HMI software with no established patch plan
No rapid process for confirming whether an infection reached critical control systems
Limited visibility across PLCs, HMIs, and controllers
Cross-segment movement requiring manual investigation
How Shieldworkz Solves Production Automation Security Challenges
Shieldworkz delivers an end-to-end OT security program designed around the operational realities of automated production environments.
Passive Asset Discovery
Every PLC, HMI, and controller across mixing, pasteurization, filling, and packaging is mapped without stopping the production line.
Malware Containment & Verification
The infected HMI is isolated and traffic history is reviewed to confirm that the infection did not spread to pasteurization or CIP controls.
OT Network Segmentation
Food-safety-critical process controls are separated from general production equipment using an IEC 62443 zone and conduit model.
OT Vulnerability Assessment
HMI and PLC software versions are reviewed to identify exposure, and vulnerabilities are addressed through a plan built around existing production windows.
Patch Scheduling Governance
A documented process is established for updating packaging HMIs around planned production windows.
OT NDR & Continuous Monitoring
Traffic is monitored for movement attempts between network segments and activity associated with the infected HMI's history.
OT SOC & Managed Monitoring
Alerts are routed to a team watching specifically for attempts to cross between zones.
End-to-End Production Automation Protection Capabilities
Production Asset Visibility
Continuous visibility across PLCs, HMIs, and controllers throughout the production environment.
Malware Containment & Verification
Rapid isolation of infected systems and verification that malware has not spread to process-critical controls.
Network Segmentation
Food-safety-critical process controls separated from general packaging and labeling equipment.
Cross-Segment Traffic Monitoring
Visibility into attempts to move between network segments.
OT Vulnerability Assessment
Review of HMI and PLC software versions to identify exposure across the production environment.
Patch Scheduling Governance
A documented process for scheduling updates around planned production windows.
IEC 62443 Zone & Conduit Alignment
Network separation structured around process-critical systems and general production equipment.
The Business Value of Protected Production Automation
Protecting production automation systems and verifying the path of an incident provides value beyond cybersecurity.
Confirmed System Integrity
Shieldworkz confirmed that the packaging-line infection never reached pasteurization or CIP controls.
Protection of Process-Critical Controls
Pasteurization and CIP systems were separated from general packaging and labeling equipment.
Complete Asset Visibility
A full inventory of PLCs, HMIs, and controllers was produced across mixing, pasteurization, filling, and packaging.
Automated Cross-Segment Monitoring
Cross-segment traffic attempts are flagged automatically instead of requiring a manual investigation.
Improved HACCP Audit Readiness
Documentation is prepared to demonstrate system integrity on short notice.
Secure Your Production Automation Environment
Your process-critical systems should not depend on assumptions.
Verify where an incident has spread. Separate critical systems from general production equipment. Monitor activity between network zones.
Talk to Shieldworkz OT Security Experts about strengthening protection across your production automation environment.
Schedule Your Free OT Security Consultation
Get the Full Production Automation Protection Use Case
Understand how Shieldworkz helped a beverage bottling and canning plant contain a malware infection, verify that it never reached pasteurization or CIP controls, separate process-critical systems from general packaging equipment, and prepare documentation demonstrating system integrity.
Book Your Consultation Today!
Strengthen your production security with better visibility, segmentation, and continuous OT monitoring. Book your consultation with Shieldworkz today.
