In modern industrial environments, network performance plays a critical role in automation, production continuity, safety and remote monitoring. Whether it’s a smart factory, oil refinery, logistics hub or power plant, every second counts. One of the biggest threats to operational efficiency is latency (the delay between sending and receiving data).
Even a small delay in communication between PLCs, SCADA systems, sensors, controllers and HMIs can lead to poor synchronisation, safety risks and equipment malfunction. That is why industries today are focusing on eliminating latency, not just reducing it.
This detailed guide explains how to eliminate latency in industrial communication networks using actionable strategies, real-time technologies and modern network design approaches.
What Is Latency in Industrial Networks?
Latency is the time it takes for data to travel from a device to its destination and return a response. In industrial environments, even milliseconds matter. High latency can cause:
- Slow machine response
- Data loss and jitter
- Automation failures
- Safety hazards
- Reduced throughput
- Inaccurate monitoring and control
Industrial networks require deterministic and real-time communication, especially in sectors like manufacturing, power distribution, mining, oil & gas and transportation.
Common Causes of Latency in Industrial Networks
Before eliminating latency, it is important to understand what causes it:
1. Outdated or Unmanaged Network Switches
Old, unmanaged switches lack features like QoS, VLANs, IGMP snooping and priority handling, which are essential for fast data flow.
2. Network Congestion
Too many devices transmitting data over the same path increases processing delays.
3. Poor Cable Quality or Long Distances
Inferior Ethernet cables or extended copper runs above 100 meters add delays and increase packet loss.
4. Incorrect Network Topology
Flat networks with daisy-chaining or unstructured layouts can slow down traffic routing.
5. Excessive Broadcast Traffic
When broadcast and multicast traffic go unfiltered, essential data packets face delays.
6. Slow Protocols and Legacy Systems
Older communication protocols like Modbus RTU, Profibus or unmanaged serial conversions slow down operations.
7. Inadequate Prioritisation Mechanisms
Without traffic segmentation or QoS, time-critical data competes with non-urgent communication.
Why Eliminating Latency Matters
Industries are rapidly moving toward real-time control, edge computing and IIoT. Even a 50–100 ms delay can impact:
- Smart Manufacturing: Robotic arms, AGVs, CNC machines and conveyor systems need near-zero delay communication.
- Energy and Utilities: Grid monitoring must respond instantly to load changes or faults.
- Process Industries: Valve control, temperature regulation and PLC coordination depend on low-latency networks.
- Safety Systems: Fire alarms, emergency shutdowns and gas detection networks cannot afford delay.
Eliminating latency improves:
- Productivity
- Monitoring accuracy
- Worker safety
- Predictive maintenance
- System uptime
- Remote diagnostics
Proven Strategies to Eliminate Latency in Industrial Networks
Below are practical and engineer-approved methods to eliminate latency across industrial environments.
1. Upgrade to Industrial-Grade Managed Ethernet Switches
Managed switches are the backbone of a low-latency network.
Features that reduce latency:
- QoS (Quality of Service)
- VLAN support
- IGMP snooping
- Port-based prioritization
- Redundancy protocols like RSTP, MRP, ERPS
- Ring network support
- Gigabit or 10G backbones
Use Case: A factory using unmanaged switches saw a 30% improvement in response time after migrating to managed Gigabit Layer 2 switches.
2. Implement Network Segmentation (VLANs)
Segmenting the network separates critical traffic from general communication. This reduces traffic load and removes unnecessary delays.
Examples:
- VLAN for SCADA and PLCs
- VLAN for CCTV surveillance
- VLAN for office IT systems
Outcome: Time-sensitive traffic gets first priority and reaches its destination without interference.
3. Prioritise Traffic Using QoS
Quality of Service ensures critical packets travel with minimal delay.
Assign higher priority to:
- Sensor data
- Control commands
- HMI communications
- SCADA instructions
Lower priority to:
- Cameras
- Web traffic
- File transfer
This ensures automation systems never face latency due to non-urgent traffic.
4. Use Fibre Optic Cabling for Long-Distance Connections
Copper Ethernet cables suffer losses and delays above 100 meters. Fibre optic cables eliminate latency over long distances thanks to faster transmission and noise immunity.
Where to use fibre:
- Between buildings
- Backbone connections
- High-EMI environments
- Long-distance controllers
Fibre also reduces packet delays caused by electromagnetic interference.
5. Optimise Network Topology
Latency increases when data takes longer paths or faces multiple hops. Use structured designs like:
- Star Topology: Simplifies routing and lowers delays.
- Ring Topology with Recovery Protocols: Ensures redundancy without sacrificing speed.
- Tree or Hierarchical Topology: Connects field devices to core switches efficiently.
Avoid daisy chaining and random switch placement.
6. Reduce Broadcast and Multicast Traffic
Broadcast storms create latency spikes. To prevent this:
- Enable IGMP Snooping for multicast traffic
- Limit broadcast domains
- Use VLANs to isolate networks
- Apply rate limits on ports
This ensures time-critical traffic moves freely.
7. Implement Redundant Paths and Faster Recovery Protocols
High-availability networks need low-latency failover mechanisms. Protocols like:
- RSTP (Rapid Spanning Tree Protocol)
- MRP (Media Redundancy Protocol)
- ERPS (Ethernet Ring Protection Switching)
These allow recovery in milliseconds instead of seconds.
8. Deploy Industrial Protocols Designed for Real-Time Data
Choose modern, low-latency protocols:
- Ethernet/IP
- PROFINET
- Modbus TCP
- EtherCAT
- OPC UA (over TSN)
TSN (Time-Sensitive Networking) guarantees deterministic communication with near-zero latency.
9. Use Edge Computing and Local Data Processing
Sending all data to a centralised server increases latency. Edge computing reduces the load by processing data closer to the source.
Benefits:
- Less bandwidth usage
- Faster decision-making
- Real-time control
- Better system redundancy
10. Monitor and Optimise Network Performance Regularly
Use tools and methods to identify latency issues early:
- Network monitoring software
- Diagnostic logs
- Port statistics
- SNMP monitoring
- Packet analyzers
Proactive monitoring minimises downtime and delays.
Additional Techniques to Minimise Latency
- Use PoE+ or PoE++ switches for faster device power and data delivery.
- Limit daisy-chaining and implement hierarchical network layers.
- Configure switch buffering appropriately.
- Disable unused ports to stop rogue traffic.
- Keep firmware and devices updated.
- Avoid mixing IT and OT networks without proper segmentation.
- Standardise devices from compatible vendors.
Case Study Example
A manufacturing plant experiencing 250 ms delays across PLC and HMI communication reduced latency to <20 ms by:
- Replacing unmanaged switches with Gigabit managed switches
- Activating QoS and VLANs
- Adding fibre optic backbone links
- Enabling IGMP snooping and RSTP
This drastically improved synchronisation, reduced downtime and prevented errors in automated tasks.
Best Network Components for Low-Latency Industrial Design
- Layer 2/3 Managed Industrial Switches
- Gigabit or 10G Uplinks
- Fibre Optic Modules (SFP/SFP+)
- Industrial Routers and Gateways
- Real-Time Protocol Support
- Edge Computing Devices
- PoE+ Switches
- DIN-Rail Mounted Hardware
Make sure the hardware supports IP30/IP40/IP67 ratings and can withstand temperature extremes, vibration and EMC interference.
How to Design a Low-Latency Industrial Network: Step-by-Step
Step 1: Assess existing bandwidth and traffic load.
Step 2: Map critical data flows (PLC-SCADA, sensors, HMIs).
Step 3: Upgrade to managed switches.
Step 4: Introduce VLANs & QoS policies.
Step 5: Replace long-distance copper with fibre.
Step 6: Reduce broadcast traffic.
Step 7: Implement redundancy protocols.
Step 8: Introduce edge computing.
Step 9: Adopt TSN-enabled devices.
Step 10: Continuously monitor and optimise.
Eliminating Latency: Future Technologies
Industrial communication is evolving. These upcoming technologies are shaping ultra-low-latency networks:
- TSN (Time-Sensitive Networking)
- Private 5G for Industrial IoT
- AI-Powered Network Optimisation
- Edge-to-Cloud Architecture
- Deterministic Ethernet
- Zero Trust Network Segmentation
Industries adopting these technologies now are establishing long-term competitiveness.
Eliminating latency in industrial communication networks is not just a performance improvement; it’s a necessity for automation, safety and uptime. By using managed switches, segmenting traffic, optimising topology, upgrading cabling, enabling QoS and VLANs, deploying fibre and real-time protocols and implementing edge computing, industries can achieve near-zero delay communication.
Whether you’re upgrading existing infrastructure or designing a new network, these strategies ensure that your systems operate with precision, reliability and speed.
Read Also: 5 Things to Check Before Buying an Industrial Gigabit Switch
Read Also: Types of Industrial Grade Network Switches
