In the first blog we outlined the Starter Pack framework for getting your OT security program off the ground by focusing on the People, Process, and Technology aspects to getting started with your OT security program. In this second blog, we dive into the importance of planning for what’s coming, unpacking OT security solution pricing and total cost of ownership (TCO), while also laying out some practical steps for getting your program started by using technology refresh cycles.
Affordability of OT security solutions can at times seem out of reach for most organizations. During the S4 ICS Security Conference which took place in Miami in February 2026, several OT visibility vendors contributed to the POC Pavilion. As part of their presentations, they had to outline their pricing. It was interesting to see that the minimum software license costs could vary from a reasonable $14,000 to a whopping $50,000 for the same deployment. But visibility is only the first step that needs to be addressed in standing up an effective OT security program. The other essential use case is using that visibility to drive protective strategies, for example, through network segmentation.
The real question isn’t “does this OT visibility solution offer all the bells and whistles”? It’s “can this product give me the foundational visibility capabilities I need to build an effective OT security program, and within budget”? Start there.
An additional factor to consider when evaluating OT security solutions is the Total Cost of Ownership (TCO) as compared to licensing fees. Factor in operational overhead of:
- How many people are required to operationalize and maintain the solution?
- What are the infrastructure requirements such as SPAN taps, new cable runs, dedicated hardware?
- Scalability: What is the exact cost for getting visibility into Purdue Level 0-1? Does the cost triple when you scale from one site to three?
Eliminate hidden costs. Look for solutions that embed security features such as OT visibility, and advanced access control into infrastructure you’re already buying rather than requiring a parallel monitoring stack. Industrial switches with integrated asset discovery, monitoring, and network segmentation capabilities are gaining ground in OT. And remember, solutions that require dedicated teams to operate are effectively more expensive than their sticker price for resource-constrained organizations. And if configured correctly, many of these solutions can provide the telemetry and diagnostic data to help folks recognize a failing or misconfigured system – or worse, a risky system with an operator that is misusing it or ignoring Standard Operating Procedure (SOP).
Many plants are due to replace unmanaged switches that are a decade old. That replacement is your opportunity to embed security into infrastructure rather than bolt it on after the fact. But it’s not just about security. Network refreshes are about enabling the business to use the latest and best-in-class technologies to drive digitalization, competitiveness, and innovation forwards. For example, delivering high wattage PoE to power new machine vision systems, reducing network latency to enable virtual PLCs, or increasing network bandwidth to fuel industrial AI applications that require real-time telemetry from the edge. Cisco’s wide range of industrial switches are designed to enable this vision: advanced networking capabilities purpose-built for modern industrial operations, with embedded OT security capabilities.
While the future is always changing, it is important to get ahead of the technology tidal wave:
- Industrial AI and software-driven industrial automation are quickly becoming a reality for many organizations. Automation and robotics generate massive data volumes. Cameras, robots, sensors, and virtual PLCs will strain networks not built for capacity or security.
- Cloud connectivity and systems will sprawl across segments, as well as connect across multiple zones and conduits. Limiting interactions by implementing segmentation based on the ISA/IEC 62443 zones and conduits model will be key.
- M&A is a common occurrence for mid-market companies. The infrastructure you build now determines how attractive your facilities will be for a buyer (or how painful the integration is likely to be).
Now is the time to start planning now to get ahead of the network and security constraints that have the potential to derail your operations. Building security-native infrastructure now avoids a costly rip-and-replace later.
OT security doesn’t require a six-figure or seven-figure investment. It requires the basics — and the basics are surprisingly affordable. Evaluate everything on TCO and operational overhead, not feature lists built for enterprises ten times your size. Use infrastructure refreshes and digitalization projects as catalysts to embed security rather than bolt it on. Arm your team with the resources they need.
Also be sure to check out Cisco’s Validated Industrial Security Design Guides that are a great free resource for designing your industrial security program.
Ready to learn more? Visit http://cs.co/CiscoIndustrialIoT