Industrial IoT Development Services
Industrial environments run on equipment that was built decades before IoT was a concept, PLCs, SCADA systems, CNC machines, and process controllers that communicate over Modbus, OPC-UA, and proprietary protocols rather than modern APIs. Getting data out of that equipment and into systems where it can drive decisions requires a different approach than standard IoT.
We build industrial IoT software for manufacturing, energy, and process industries: SCADA integration, OPC-UA and Modbus protocol support, predictive maintenance data pipelines, and the MES and ERP integration that closes the loop between what your equipment is doing and what your business systems record.
OPC-UA, Modbus, and legacy industrial protocol integration alongside modern IoT
SCADA integration without disrupting existing operational technology
Predictive maintenance pipelines connecting sensor data to maintenance workflows
MES and ERP integration to close the loop between production and business data
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The problem
Production data locked in SCADA systems and operator panels that nothing else can read?
Running scheduled maintenance on equipment that has sensor data showing actual condition?
Short answer
Industrial IoT development connects plant equipment, PLCs, SCADA systems, CNC machines, and sensors, to software that turns machine data into decisions. It integrates industrial protocols like OPC-UA and Modbus, bridges the OT-IT divide with edge or cloud pipelines, and feeds dashboards, alerting, and predictive maintenance so production teams act on live data, not end-of-shift reports.
Key takeaways
Trusted by
The gap between what industrial equipment knows and what your business systems record is where production problems hide. Equipment showing early signs of bearing failure, captured in vibration and temperature data, while the maintenance system schedules the next inspection for next quarter. Production yield drifting below target while the MES records output counts but not the sensor readings that explain why.
Industrial IoT development closes that gap. It connects the OT layer (PLCs, SCADA, sensors) to the IT layer (MES, ERP, CMMS). Production data then drives operational and business decisions in real time, not at the end of a shift or the end of a week.
According to McKinsey Digital, predictive maintenance typically reduces machine downtime by 30 to 50 percent and increases machine life by 20 to 40 percent. For production teams on thin margins, the gap between a scheduled intervention and an unplanned line stoppage is often the gap between hitting output targets and missing them.
Capabilities
OPC-UA client integration for SCADA platforms that subscribes to tag changes, receiving updates only when values move beyond a configurable deadband. The integration is deployed read-only: no setpoint writes, no changes to SCADA configuration or PLC programs, so production-critical systems carry no added risk.
Modbus TCP and RTU polling for legacy PLCs, VFDs, energy meters, and process controllers where OPC-UA is not available, which describes most equipment installed before 2015. Every protocol choice is documented in a technical assessment your OT team reviews and approves before work starts.
Sensor data pipelines structured to support predictive maintenance models, where the diagnostic signal is buried in high-frequency raw data. Temperature baselines, statistical process control, and energy anomaly detection catch emerging faults before fixed alarm limits trip, and when a model exceeds its alert threshold a work order is created in your CMMS with the readings pre-populated.
Real-time production dashboards built around OEE calculated from live equipment data rather than end-of-shift manual entry, displayed at machine, line, and site level with drill-down to individual downtime events. A projected end-of-shift count gives supervisors time to intervene before the number is final.
Bidirectional integration between the IoT platform and the MES/ERP layer, so equipment readings are recorded against the right production order and planners stop re-keying paper shift reports by hand. Predictive alerts and downtime events create CMMS work orders with sensor readings and fault context attached.
Edge computing architecture for plant floors where cloud latency is unacceptable, connectivity is restricted, or raw production data must stay on the site network. A local MQTT broker and time-series buffering keep collection and alerting running through cloud outages, with store-and-forward sync forwarding data in order once the connection recovers.
Most focused industrial IoT projects run $40,000 to $100,000. The range is wide because the scope is wide: pulling data from one CNC machine over Modbus into a single dashboard is a different build from a multi-line deployment with predictive maintenance and ERP write-back. Start with a first phase that proves the data flow on one equipment type, then expand once the OT team trusts it.
One equipment type or line, one or two protocol integrations, read-only SCADA or Modbus polling, a real-time dashboard, and one downstream system (MES or CMMS).
Modbus RTU, Allen-Bradley, Siemens S7, or a historian-database bridge where no OPC-UA server exists.
Vibration and temperature baselining, statistical process control, and automatic CMMS work orders with readings attached.
Industrial PC, local MQTT broker, and store-and-forward sync for plant floors with restricted or unreliable connectivity.
SAP RFC/BAPI, Oracle, or Dynamics 365 integration so readings post against the right production order.
Repeating the proven pattern across lines and sites, with central monitoring.
A focused first phase lands near the bottom of the band. A full multi-line deployment with predictive maintenance and ERP write-back reaches the top and beyond. We scope every integration point before pricing it, so nothing is estimated blind.
Tell us your equipment types, protocols, and the operational decisions you need to make from that data. We'll design the integration architecture and give you a fixed cost.
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What clients say
Three-year average engagement. Founders and operators describing the work in their own words. No marketing varnish.
USAAll of the sprints were completed on schedule and on budget. We highly recommend RaftLabs!
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Read moreSCADA integration depends on what the system exposes. Modern SCADA systems expose OPC-UA servers, we connect an OPC-UA client that reads tags, subscribes to data changes, and forwards data to the IoT platform. Older systems often only support Modbus TCP or Modbus RTU, we deploy a Modbus data collector that polls registers on a defined schedule and publishes data upstream. Where neither protocol is available, we use database replication (the SCADA historian database), screen scraping, or hardware data loggers attached to the equipment's communication bus. We assess each integration point during scoping and choose the least disruptive method that meets the data requirements.
OT (operational technology) is your production-critical equipment and control systems, PLCs, SCADA, DCS, and the networks they run on. These systems are optimized for reliability and real-time control, not connectivity, and they often run on isolated networks for safety and security reasons. IT is your business systems, ERP, MES, CMMS, and cloud infrastructure. Industrial IoT integration bridges the two layers: pulling data from OT systems through a secure integration point (data diode, DMZ, or managed gateway), processing and contextualizing it, and making it available to IT systems that need it. The key constraint is that OT systems must not be put at risk by the integration, we design the data flow so traffic moves from OT toward IT, not the other way around.
Most industrial environments don't have reliable internet connectivity on the plant floor, and many use isolated OT networks by design. We address this with edge processing: an edge gateway or industrial PC on the plant floor runs the data collection, aggregation, and alerting logic locally. Results and summaries are synced to cloud systems when connectivity is available, and the edge system continues operating independently if the connection drops. Critical alerts can be delivered over local networks (to on-floor displays or local notification systems) without requiring cloud connectivity. We scope the edge vs cloud split based on your connectivity situation, latency requirements, and what decisions need to be made on the floor vs in a control room.
Most industrial IoT projects run $40,000 to $100,000. A first phase starts near $40,000: one equipment type or line, one or two protocol integrations, a real-time dashboard, basic alerting, and one downstream system (MES or CMMS). It grows toward $100,000 as you add protocols, predictive-maintenance pipelines, edge deployment, and full MES/ERP write-back across multiple lines. Cost tracks the number of integration points, protocol complexity, the edge-versus-cloud split, and how many systems the platform must feed. We scope every integration point before pricing it.
Work with us
We scope Industrial IoT Development in 30 minutes. You walk away with a clear cost, timeline, and approach. No commitment required.