Why Manufacturing CIOs Are Extending Zero Trust Inside the Factory Perimeter-based security models are unraveling in industrial environments where network boundaries have grown complex. Traditional firewalls struggle to protect systems that now routinely connect across cloud services, remote monitoring workflows, and Internet of Things (IoT) devices. Many industrial systems, built before today's interconnected landscape, lack advanced security features and can’t easily adapt to modern protection approaches.Moving beyond perimeter-based security to deploy zero trust within the factory requires overcoming several key barriers—such as the inability to install agents on legacy devices, the need to minimize lateral threat movement, and the imperative to maintain uninterrupted production uptime. While traditional models fall short in these dynamic environments, Zscaler’s agentless approach enables rapid, non-disruptive deployment across diverse OT systems. It delivers granular control, reduces the attack surface, and prevents lateral movement of threats like ransomware—all without compromising operational continuity.The realistic path forward will require IT and OT leaders to explore hybrid approaches that blend traditional segmentation frameworks, such as the Purdue Model, with zero trust principles. This method allows teams to apply more granular security controls without disrupting established industrial control system (ICS) infrastructure.Understanding the intersection of IT, OT, and infrastructure securityThe industrial edge now converges IT and OT. Production floors—once physically separate from corporate networks—connect with cloud-enabled systems for analytics, maintenance, and workforce collaboration. Heads of infrastructure and operational leaders share responsibility for protecting these environments without compromising production, but they face several challenges:Perimeter-based security architecture that was never designed for connectivity across multiple sitesReal-time operations that demand minimal downtimeSiloed oversight between IT and OT teams, complicating security managementThe Purdue Model has long guided ICS security by separating the layers of ICS/OT and IT systems and isolating them to contain threats. However, digital transformation—including IoT and cloud adoption—has made industrial networks so integrated that this “air gap” approach simply isn’t effective anymore.Why traditional IT security models fall short in industrial environmentsPerimeter-based security architectures were designed for a world that no longer exists. These models assume a clear boundary between trusted internal networks and untrusted external systems—but such boundaries continue to blur in industrial settings. The explosion of connected devices, remote access requirements, and the need for continuous operational insights demand a more dynamic security model.Furthermore, many industrial systems and devices were engineered decades ago. They weren’t built to meet modern security standards—making them potential entry points for attackers when connected to interconnected IT-OT networks. Traditional air gaps and Purdue Model segmentation provide a strong security foundation, but with IoT devices and sensors often integrating directly with cloud applications, ICS security requires more agile control than static firewalls.Barriers preventing zero trust adoption for IT leaders and infrastructure headsZero trust can solve key ICS security challenges by enforcing adaptive, context-based application access without physically segmenting IT and OT layers. However, a few common obstacles tend to slow zero trust adoption in industrial settings, including:Perimeter-based systems. These systems aren’t compatible with zero trust frameworks and can be difficult to retrofit with continuous verification—one of zero trust’s main principles.Operational risks. Many industrial leaders share concerns about disruptions during any security transformation.Siloed visibility. The lack of unified oversight between IT and OT environments creates blind spots in security management.Resistance to change. Operational norms or priorities may conflict with new security approaches, resulting in pushback from internal teams. Beyond these hurdles, organizations must also navigate deeper organizational and regulatory complexities that can further impede adoption.Aligning IT, OT, and infrastructure leadershipEach group brings its own priorities: IT security managers focus on cyberthreat mitigation, OT professionals prioritize uninterrupted production, and infrastructure directors balance reliability with modernization. While these priorities may differ, successful security outcomes depend on collaboration.Zero trust has proven effective in corporate and data center environments, but factory settings introduce unique OT requirements that have historically slowed adoption. Zscaler offers a paradigm shift by applying zero trust principles specifically to the industrial edge and interior operations. Through advanced device segmentation and Privileged Remote Access (PRA), Zscaler delivers secure, agentless solutions purpose-built for uptime-critical OT systems—helping organizations minimize operational risk without compromising productivity.By simplifying cross-functional collaboration, Zscaler enables IT and OT teams to align on shared goals. Agentless deployment minimizes attack surfaces, enforces zero trust segmentation, and ensures real-time visibility across both modern and legacy systems—accelerating OT/IT convergence while preserving operational continuity. Navigating regulatory complexitiesIndustrial sectors, including manufacturing, energy, and transportation, follow strict regulations to protect critical infrastructure. These guidelines can slow technology adoption and raise questions about how zero trust intersects with existing compliance practices.Regulators, however, increasingly recognize that greater visibility and stronger access controls improve cyber resilience. Zero trust keeps businesses compliant by providing documented security checks, detailed logs of approved connections, and micro-level access controls.Solutions to unlock zero trust at the industrial edgeIndustrial organizations can overcome zero trust adoption barriers by:Conducting security assessments tailored to OT environments. These specialized evaluations must account for the unique characteristics of industrial systems, including legacy equipment, proprietary protocols, and mission-critical operational requirements.Bridging IT and OT silos. Establish regular communication channels, joint working groups, and integrated planning sessions to break down historical barriers between these teams and align on shared security goals.Leveraging cloud-based zero trust offerings. These solutions provide a flexible pathway to integrating zero trust principles while respecting existing Purdue Model segmentation. Deploying zero trust to less critical systems first can help build confidence in its value. Once leadership teams see that production stability remains intact, expanding zero trust to more sensitive areas feels easier.Why agentless is critical inside the factoryZero trust adoption inside the factory environment requires solutions that address the limitations of legacy OT systems and industrial sensors—many of which cannot support traditional security agents. Zscaler provides agentless segmentation and isolation capabilities that ensure rapid deployment and non-intrusive operation. By eliminating dependency on exposed ports or software agents, Zscaler protects critical systems while maintaining the uptime that is vital to operational continuity. This agentless approach is foundational to applying zero trust inside factories without adding complexity or risking disruption.Microsegmentation for legacy and industrial systemsMicrosegmentation breaks down network segments into smaller, isolated zones to reduce the attack surface and limit lateral movement. Each device or workload has a specific security policy, so unauthorized data flows are blocked—even if an attacker infiltrates one area. In industrial and hybrid environments, microsegmentation provides effective protection for modern devices like IoT sensors as well as older machinery that may lack built-in security. It also reduces downtime risks since it prevents a vulnerability in one part of the network from cascading into production-critical systems.Why Zscaler Is the key to unlocking industrial zero trustThe Zscaler Zero Trust Exchange™ unifies IT, OT, and infrastructure security under a single, cloud-native framework that scales across industrial networks. It extends zero trust security and segmentation to interconnected IT-OT systems so you can maintain complete visibility and control of all IoT devices and servers across your organization.With the Zero Trust Exchange™, you get:Real-time threat protection that scales to inspect all traffic and block threats immediatelySeamless IT-OT integration through policy-based controls that preserve production uptimeMicrosegmentation for hybrid environments to secure critical data flows and industrial devicesPrivileged remote access to IoT and OT devices with full cybersecurity and governance controlsZscaler also recently acquired Airgap, which leverages the Purdue Model to neutralize advanced cyberthreats on OT systems, IoT devices, and agent-incapable devices. Adding Airgap’s capabilities to the Zero Trust Exchange™ means industrial organizations can enjoy a fully integrated security solution that eliminates lateral threat movement while reducing the operational complexity associated with perimeter-based solutions.Leading the way in zero trust adoption for industrial leadersIT and OT professionals must address an evolving threat landscape while juggling performance demands, siloed visibility, regulatory constraints, and other challenges unique to ICS environments. Zscaler is redefining zero trust for industrial leaders by implementing advanced segmentation and Privileged Remote Access (PRA) aligned with the Purdue Model. This approach enables factories to preserve critical workloads and industrial processes while addressing the connectivity-driven challenges of Industry 4.0. With capabilities like agentless device isolation and seamless access controls, industrial organizations can confidently adopt zero trust without adding operational complexity or compromising uptime.Secure your connected future today with Zscaler. Explore our industrial security solutions or request a demo to learn more.
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