Pioneering Renewable Energy Manufacturing in India

This case study is about how Networks & Cybersecurity provide the backbone for modern manufacturing processes, enabling secure connectivity & communication, and data-driven decision-making, all of which are integral to the efficiency and optimization of manufacturing operations.

Industry 4.0


  • Industrial Network Establishment: Designed and installed a state-of-the-art IT and OT network infrastructure from the ground up, setting a new standard for operational efficiency in the renewable energy sector.
  • Adoption of Industry 4.0 principles: Used smart technology and digital innovation ensuring real-time data exchange between manufacturing processes and business systems to improve decision-making and operational agility.
  • Uncompromised Security: The implementation of a robust cybersecurity framework has fortified the plant's defenses, ensuring compliance with industry standards, and safeguarding against potential threats.


As a leader in the renewable energy sector, our client is committed to pioneering sustainable solutions. Their latest endeavor involves the establishment of India's largest manufacturing plant dedicated to renewable energy. This project is a testament to their dedication to environmental sustainability but also demonstrates their commitment to harnessing advanced technology to redefine industry standards


The client wanted to create a manufacturing hub that not only meets today's needs but is also ready for the challenges of tomorrow. Central to this vision was a set of key requirements designed to ensure that the facility is efficient, flexible, and secure. Here is what they were looking for:

  • Adoption of Industry 4.0 principles: By leveraging smart technology and digital innovation, they wanted to create a manufacturing environment that leverages the latest in digital innovation for enhanced efficiency and adaptability
  • Automation and Control: Implementation of comprehensive Industrial Automation and Control Systems (IACS) to streamline operations, supported by Autonomous Mobile Robots (AMRs) for optimal material handling and logistics.
  • Seamless Connectivity: Development of a fully interconnected ecosystem that integrates Information Technology (IT) with Operational Technology (OT), facilitating real-time data exchange and analytics to improve decision-making and operational agility.
  • Network Resilience: They wanted robust & resilient networks capable of withstanding various challenges, to ensure continuous production and so that it can provide complete operational visibility for excellence in execution.
  • Uncompromised Security: Protection against cyber and physical threats, encompassing data communication security, access controls, and measures to safeguard operations and intellectual property.

Recognizing the complexity and the critical nature of this project, our client sought a partner who could truly empathize with their unique challenges. They needed someone who would not just supply a service, but who would journey with them from the initial design phase all the way through to the final implementation. This partnership would be built on a deep understanding of their vision, ensuring that every solution provided is not just effective but also perfectly aligned with their long-term goals.


When Velocis set out to craft the network infrastructure for our client’s renewable energy manufacturing plant, they began with a clear blueprint for success. Their mission was to design a system that not only met the client’s immediate operational needs but also one that was future-proof, secure, and capable of supporting growth and innovation. Here is how we approached the design:

  • Industrial Networking: Beginning with a network backbone of ruggedized Cisco IE (Industrial Ethernet) switches, we established a robust and resilient framework designed to withstand the rigors of the industrial environment, ensuring that all aspects of the Industrial Automation and Control Systems (IACS) communicate seamlessly.
  • Advanced Wi-Fi for Seamless Connectivity: Rolled out Wi-Fi 6 that allowed for uninterrupted communication across the facility, bridging the gap between operations and administration.
  • Industrial Wireless at Process Level: Utilized industrial-grade wireless solutions to offer unparalleled visibility into the manufacturing processes, enabling real-time monitoring and automation through advanced wireless technologies.
  • Network Management through DNAC: Cisco's DNA Center is being used for centralized network oversight, streamlining operations, automating routine processes, and delivering critical performance analytics.
  • Enhanced OT Security with Cyber Vision: This enhanced security within OT operations, offering deep visibility into OT protocols and real-time detection of anomalies and vulnerabilities, thus fortifying the manufacturing plant against cyber threats.
  • Secure IT/OT Integration with Industrial Demilitarized Zone (IDMZ): We established an IDMZ, creating a safe buffer for data exchange between IT and OT systems and safeguarding against external threats.
  • Stringent Network Access Control (NAC): Set up measures to ensure network access is restricted to authenticated devices and personnel, significantly heightening security against unauthorized breaches.
  • Robust Perimeter Defense with Next Generation Firewalls (NGFW): Deployed next-generation firewalls at the network's perimeter, equipped with advanced features such as intrusion prevention, application awareness, and threat intelligence, further enhancing the overall security posture of the network infrastructure.
  • Edge Computing: Lastly, we proposed Cisco’s Hyperconverged systems to deliver a flexible, scalable, and efficient infrastructure solution, perfectly in tune with the dynamic and demanding nature of manufacturing operations.

With this strategic framework in place, Velocis did not just lay down wires and switches; they laid the groundwork for a future where the client's manufacturing operations could thrive on efficiency, security, and adaptability. This well-thought-out infrastructure lays down the tracks for the client to accelerate towards impactful business outcomes, propelling them forward in efficiency, security, and innovation.

Business Outcomes

With the successful deployment of a state-of-the-art IT and OT network infrastructure at the renewable energy manufacturing plant, our client witnessed a transformation that propelled their operations into a new era of efficiency and security. The new system, fortified by a resilient, robust, and scalable design, was a significant change in several key areas:

  • The client experienced streamlined processes.
  • The modular design of the network provided the agility needed to respond to market demands quickly. This adaptability means the client can now scale their operations up or down with ease.
  • A robust cybersecurity framework was put into place, enhancing the security posture of the manufacturing plant. This ensures compliance and mitigates risks, creating a trustworthy environment for all stakeholders.
  • The intervention led to a reduced Total Cost of Ownership (TCO) and an increased Return on Investment (ROI), marking a significant financial win for the client, and justifying the investment in upgrading their infrastructure.
  • Critical to their mission, the new network infrastructure has a reduced carbon footprint and optimizes resource use, reinforcing the client's commitment to environmental stewardship.

Industry 4.0

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