Introduction
What is a system integrator?
A system integrator is a company or professional that designs, implements, and supports the connection of multiple industrial systems into one cohesive operation. In manufacturing environments, this often involves combining equipment, software platforms, network infrastructure, and custom code to enable automation, data collection, and centralized control. While some integrators focus purely on control systems, others offer deeper integration services that span SCADA, MES, cloud platforms, and even ERP. Their role is to make sure all systems communicate effectively and function reliably within a larger operational framework. Unlike OEMs or product vendors, system integrators are not tied to a specific hardware or software stack. Instead, they focus on solving operational challenges using the best available tools and practices, which is what makes them so valuable in complex manufacturing environments.
Why this article matters now
The manufacturing industry is entering a new era of complexity, connectivity, and competitive pressure. Companies are being pushed to modernize, extract more value from their data, and adapt to supply chain volatility. As a result, there is a growing demand for trusted partners who can deliver not just automation but transformation. Yet many leaders still misunderstand the role and scope of a system integrator. They think of integrators as temporary vendors who wire panels or write some PLC code, rather than long-term collaborators who can guide architectural decisions, bridge the IT and OT divide, and help build scalable systems that support business goals. This article aims to change that by giving a clear, detailed, and realistic picture of what system integrators do, why they matter, and how to work with them effectively.
Who this article is for
This post is written for plant managers, engineering directors, IT leaders, operations executives, OEM product managers, and consultants who want a deeper understanding of how system integrators fit into modern manufacturing environments. Whether you are launching a greenfield project, upgrading legacy infrastructure, expanding your data strategy, or simply exploring ways to modernize operations, this guide will help you assess whether a system integrator should be part of your solution. Even if you have worked with integrators in the past, the landscape is shifting. More organizations are now demanding strategic thinking, cross-functional expertise, and support beyond commissioning. If you are looking for clarity and direction in this space, you are in the right place.
Joltek’s perspective on system integration and modernization
At Joltek, we believe system integration is not just about connecting devices, it is about enabling progress. Our team has worked across some of the most challenging manufacturing environments in North America, supporting everything from controls upgrades to full digital transformation initiatives. What we have learned is that the best integration work happens when strategy, engineering, and execution align. Our perspective is shaped by real-world implementation experience, not vendor marketing or high-level frameworks. We understand the nuances of legacy systems, the politics of IT and OT teams, and the need for long-term reliability. Joltek approaches every integration project with a bias toward transparency, scalability, and ownership. We are not here to sell you a system. We are here to help you make your systems work better together.
The Role of a System Integrator
Definition and Core Responsibilities
A system integrator is a professional or company that connects separate automation systems, hardware, and software into a unified, reliable solution that serves the needs of a manufacturing operation. Their core responsibility is to ensure that machines, sensors, controls, networks, and software platforms function as one coordinated system. This includes designing system architecture, writing and validating code, integrating devices from different vendors, managing data flow, and providing long-term support. The best integrators bring technical expertise, project management skills, and a deep understanding of operational goals. They are not just wiring panels or installing software. They are creating the foundation on which manufacturing systems operate, evolve, and compete.
Differentiating Between a System Integrator and a Control Systems Engineer, OEM, or IT Consultant
Although system integrators often work alongside control engineers, OEMs, and IT consultants, their role is fundamentally different. A control engineer may program a PLC, but a system integrator goes further by designing the architecture across the entire process, selecting the right components, and ensuring that all layers communicate properly. While OEMs typically focus on a specific machine or product line, integrators work across multiple systems and brands to enable plant-wide functionality. IT consultants bring value in cybersecurity, cloud infrastructure, or enterprise platforms, but they often lack knowledge of plant-floor equipment and real-time operational constraints. A system integrator bridges this divide. They speak both IT and OT fluently and build practical solutions that operate in the real world of manufacturing.
Scope of Services Offered
The range of services offered by system integrators depends on their technical capabilities and industry focus. The most successful integrators go beyond traditional control work and support initiatives across the entire stack. Some of the most valuable services include the following.
Automation and Controls Integration
System integrators are often brought in to design and program PLCs, configure HMIs, and commission machine control logic. This includes working with Rockwell, Siemens, Omron, and other industrial platforms. A strong integrator will ensure not only that the system works, but that it is documented, scalable, and maintainable. They create structured code, apply naming conventions, and support operators during startup and handover.
SCADA, MES, and Historian Deployments
Many manufacturers rely on integrators to deploy supervisory systems like SCADA, MES, and data historians. These tools provide visibility, traceability, and production control. Integrators work with platforms such as Ignition, AVEVA, and Proficy to create dashboards, capture quality data, track work orders, and interface with upstream systems. The true value comes when these tools are designed to reflect the real workflows of the plant, not just technical requirements.
For readers interested in modern SCADA strategies, this article on SCADA systems dives deeper into architecture and integration practices.
IT and OT Convergence and Network Architecture
Modern system integrators increasingly support network design, segmentation, and security across both IT and OT domains. They help clients design VLANs, set up managed switches, install industrial firewalls, and enforce cybersecurity best practices. This is no longer optional, especially with remote access, IoT sensors, and cloud connectivity becoming standard. A well-designed network enables performance, visibility, and compliance.
Custom Software Development
Some integrators provide custom development to close the gap between standard software platforms and unique client needs. This could include building mobile dashboards, web-based reporting tools, or middleware layers that connect SCADA with ERP. In some cases, it involves scripting, APIs, or edge-based applications. Custom work helps manufacturers get the most out of their systems without overhauling everything.
Retrofitting and Modernization of Legacy Equipment
Legacy equipment can be difficult to support, but integrators often play a key role in keeping older systems running while preparing for modernization. They may upgrade obsolete PLCs, replace unsupported SCADA platforms, or add data collection to machines that were never designed to be connected. This is one of the most common and cost-effective reasons to hire a system integrator, especially in facilities where capital is limited.
For a deeper look at why modernization matters, explore Joltek’s article on upgrading legacy automation.
Commissioning and Validation
System integrators do not just build the system. They also test it, validate it, and support it in the field. This includes Factory Acceptance Testing, Site Acceptance Testing, and full commissioning on the plant floor. In regulated industries such as pharmaceuticals or medical devices, they also support validation and documentation. A good integrator will remain involved until the system is stable and the client is confident in ownership.
Types of System Integrators
Based on Industry Focus
System integrators often tailor their services to specific industries, aligning with the operational standards, compliance requirements, and production models of each environment. An integrator’s industry focus shapes their design decisions, technology stack, and implementation approach, which is why industry alignment is one of the most important criteria when selecting a partner.
Food and Beverage
In food and beverage manufacturing, system integrators must design solutions that meet stringent safety regulations, enable rapid changeovers, and support real-time traceability. These facilities often rely on batching systems, hygienic equipment design, and strong integration between SCADA, MES, and quality systems. The ability to track and trace production across ingredients, lines, and shifts is a core requirement in this sector. Integrators in this space often work with platforms like Rockwell FactoryTalk Batch, Siemens S7, and Ignition.
Pharma and Life Sciences
Pharmaceutical and life sciences projects require precision, validation, and strict regulatory compliance. System integrators must implement systems that adhere to 21 CFR Part 11, GAMP guidelines, and audit-ready practices. Everything from electronic signatures to audit trails and recipe enforcement must be configured with quality and compliance in mind. Integrators in this field often specialize in validated control environments, cleanroom automation, and electronic batch records.
Automotive
In the automotive sector, integrators play a key role in high-throughput automation, robotics, and plant-wide coordination. Automotive systems demand millisecond-level control, detailed diagnostics, and integration with production execution systems. Here, integrators must balance real-time performance with traceability, often working in multi-vendor environments involving Siemens, Rockwell, Fanuc, ABB, and others.
Consumer Packaged Goods
The CPG space prioritizes speed, flexibility, and efficiency. Integrators often deploy modular lines, vision systems, and machine analytics to help plants manage frequent product changes and SKU diversity. Success in this space depends on the ability to design flexible automation that scales without sacrificing uptime or yield.
Energy and Utilities
In the energy sector, system integrators support power generation, transmission, and distribution by deploying robust SCADA systems, load control, and monitoring networks. Projects often involve remote telemetry units, redundant communication systems, and cybersecurity best practices. Safety and system availability are non-negotiable in these projects.
Water and Wastewater
Water treatment facilities rely on integrators to implement highly reliable control systems that manage flow rates, chemical dosing, pumping schedules, and compliance reporting. These systems are designed for longevity and resilience, often with local and remote redundancy. Integrators in this sector often use open protocols like Modbus and DNP3 and must work with public utility standards.
Based on Specialization
Aside from industries served, system integrators also differentiate themselves based on the specific technologies and layers of the stack they focus on. Understanding these specializations helps ensure the right expertise is brought to the right problem.
PLC and Controls Integrators
These integrators focus on machine-level control and logic development. They are experts in ladder logic, structured text, and commissioning across PLC platforms such as Rockwell, Siemens, and Omron. They are essential for new equipment integration, retrofits, and production line upgrades.
SCADA and MES Integrators
Some firms specialize in the design and deployment of supervisory systems that sit above the controls layer. They implement SCADA and MES platforms to enable visibility, data capture, and process coordination. A good SCADA or MES integrator understands both the technical configuration and the operational goals of the facility.
For a deep dive into SCADA architecture, you may want to read the comprehensive SCADA guide on Joltek if available.
Robotics Integrators
Robotics integrators focus on programming and installing robotic cells, whether for palletizing, assembly, welding, or inspection. They work with brands such as Fanuc, ABB, KUKA, and Universal Robots. They also ensure that robots are safely and efficiently integrated into broader automation systems, often including vision and safety systems.
Vision Systems Integrators
These specialists configure machine vision and quality inspection systems, including cameras, lighting, and processing logic. Their work is critical in high-speed packaging, quality control, and automated inspection. Success depends on understanding both optics and integration with PLC or SCADA systems.
Enterprise Integration
Enterprise-focused integrators specialize in connecting plant systems with business systems such as ERP, cloud analytics, or data lakes. They may work with protocols like OPC UA, MQTT, or REST APIs and often develop custom middleware. This specialization enables leadership to make decisions based on real-time plant data.
Boutique versus Large-Scale Integrators
Boutique integrators are smaller firms that often bring deep expertise in a specific domain or region. They offer agility, flexibility, and direct access to senior engineers. They are a strong fit for specialized or high-touch projects that require close collaboration and fast decision-making.
Large-scale integrators often have international reach, broader service offerings, and structured processes. They are ideal for multi-site rollouts, global standards, and high-volume support. Their strength lies in consistency, scalability, and project management infrastructure.
When and Why You Need a System Integrator
Common Triggers for Engaging an Integrator
There are specific scenarios in manufacturing where the involvement of a system integrator becomes not only helpful but essential. These are moments when technical complexity, regulatory risk, or business impact is high enough that internal resources cannot deliver the required outcome alone. Engaging a system integrator is often the difference between a project that merely functions and one that delivers strategic value.
Greenfield Project or Expansion
When building a new facility or expanding operations, system integrators play a central role in designing the control architecture, selecting the right hardware and platforms, and connecting machines, networks, and software into a single coherent system. This is the stage where foundational decisions are made that impact scalability, maintenance, and data flow for years to come. Integrators help define the technical roadmap, coordinate with OEMs, and ensure interoperability between systems.
Line Upgrades and Retrofits
Upgrading part of a line or retrofitting legacy machinery introduces complexity, especially when new components must work with old systems. A good system integrator will reverse-engineer legacy logic, document undocumented equipment, and implement updates without disrupting production. This ability to modernize without starting from scratch is one of the most valuable services an integrator can offer, especially in facilities with capital constraints.
For a deeper exploration of this topic, you may find Joltek’s article on modernizing legacy automation systems highly relevant. It explains how to reduce risk and extend the life of existing assets through thoughtful integration.
Obsolescence Risk
Aging PLCs, unsupported SCADA platforms, or failing HMI panels introduce reliability concerns that can shut down a production line. Integrators assess the current state of systems, identify obsolete components, and create a roadmap for replacement. This work is often invisible until something breaks, but it is foundational for operational stability. Risk grows when hardware or software is no longer supported, and a structured modernization plan becomes necessary.
Compliance and Validation
For regulated industries like pharmaceuticals, medical devices, or food production, system changes must meet specific compliance frameworks such as 21 CFR Part 11 or GAMP. Integrators with experience in validation environments support the creation of User Requirement Specifications, Functional Specifications, testing protocols, and audit-ready documentation. Their familiarity with both automation and compliance ensures that technical upgrades do not compromise regulatory standing.
Data Visibility and Reporting Needs
As manufacturers seek to improve decision-making, they often face gaps in real-time data availability. Machine data may not be connected to plant historians, quality systems, or ERP platforms. System integrators can bridge this gap by deploying SCADA systems, historians, custom dashboards, or cloud connectors. When done well, this unlocks new levels of operational insight without overwhelming teams with raw data.
For a closer look at data challenges in manufacturing, Joltek’s content on unifying plant data outlines the pitfalls and opportunities of scaling visibility across OT systems.
IT and OT Misalignment or Fragmentation
It is common for manufacturers to have strong but separate IT and OT teams. This often leads to siloed systems, duplicated efforts, and conflicting priorities. System integrators bring both sides to the table. They speak the language of plant-floor operations while understanding IT standards and governance. They serve as the bridge that aligns performance, cybersecurity, and infrastructure across both domains.
Build versus Buy versus Integrate
When faced with a new challenge, manufacturers often ask themselves whether to build a solution in-house, buy a commercial off-the-shelf system, or integrate existing tools. This is rarely a simple decision. Building allows for full control but demands deep technical resources. Buying speeds up deployment but may lack flexibility. Integration provides a middle ground, allowing the company to leverage what they already own while extending capabilities through new systems. System integrators help organizations navigate these tradeoffs by providing realistic assessments of effort, risk, and sustainability.
An integrator may recommend standardizing on a platform, creating a data layer, or using open protocols to ensure long-term adaptability. The right decision often depends on budget, timeline, internal expertise, and how central the problem is to the business strategy.
Cost versus Value of System Integration
Hiring a system integrator is often seen as an added expense, especially when internal engineers already exist. But this view misses the broader picture. The true value of a system integrator lies in reducing risk, accelerating deployment, and delivering systems that work reliably the first time. Their outside perspective often surfaces issues that internal teams overlook due to proximity or legacy bias. A failed project costs more than a properly scoped integration.
Moreover, integrators bring reusable frameworks, past experience, and vendor relationships that shorten development time and improve support. When systems are architected correctly from the start, operational downtime is reduced, troubleshooting becomes easier, and future upgrades are less painful.
How System Integrators Work
Discovery and Requirements Gathering
Every successful system integration project begins with a discovery phase. This is where the integrator works closely with your team to understand current systems, production goals, pain points, and constraints. The quality of the final outcome is directly tied to the depth and clarity of the initial discovery process. This involves reviewing existing control architectures, network layouts, user workflows, software platforms, and organizational priorities. During discovery, integrators often conduct interviews with operators, engineers, IT personnel, and leadership. The result is a shared understanding of what needs to be solved and why it matters to the business.
Functional Specification Documents and URS Development
Following discovery, system integrators document the requirements in structured formats. Two key deliverables are the User Requirement Specification and the Functional Specification Document. The URS outlines what the system must do from the user’s perspective. It defines expectations for performance, availability, compliance, and usability. The FSD translates those expectations into technical logic, workflows, data models, and control sequences. A well-written FSD ensures alignment between operations, engineering, and IT and reduces scope creep during implementation. These documents also serve as a reference during testing and future upgrades.
Architecture Design
Once requirements are finalized, the system integrator begins designing the overall architecture. This includes selecting hardware, defining network topology, identifying protocols, and mapping out the control and software stack. Good integrators design for both today’s needs and tomorrow’s changes, balancing performance, scalability, and maintainability. Network architecture may include segmented VLANs, firewalls, managed switches, and redundant links. On the software side, the integrator will define how data flows between PLCs, HMIs, SCADA systems, MES platforms, historians, and external systems like ERP or cloud analytics.
For facilities considering improvements to their infrastructure, Joltek’s article on unified plant architecture outlines key considerations for scalable and future-ready design.
Programming and Configuration
Once the architecture is approved, programming begins. This involves writing control logic for PLCs, configuring operator interfaces for HMIs, scripting in SCADA platforms, and setting up MES workflows. The integrator applies standards, naming conventions, and reusable templates to maintain consistency and reduce debugging time. Skilled integrators also leave behind clean, documented, and version-controlled code to support maintenance and future upgrades. Programming may involve structured text, ladder logic, function block diagrams, or higher-level scripting depending on the platforms involved.
If you're interested in how real-world PLC logic is structured, Joltek has published a deep dive into PLC data structures and edge cases based on practical experience.
FAT, SAT, and On-Site Commissioning
After configuration, the system undergoes a series of tests before going live. The Factory Acceptance Test is usually performed in the integrator’s environment to validate the functionality against the FSD. Once the system arrives on-site, the Site Acceptance Test ensures that it works correctly in the real environment. Commissioning involves physical installation, I/O checkout, tuning of control loops, and real-time validation with production. The commissioning phase is where theory meets reality, and the integrator’s adaptability often determines how smoothly the transition to production occurs.
Post-Deployment Support and Change Management
Even after the system is running, integrators provide support for troubleshooting, optimization, and system updates. They may offer on-call service, change request handling, or performance audits. Support is not just about solving issues, it is about enabling your internal teams to take ownership and evolve the system over time. In facilities undergoing digital transformation, this may include training plant personnel, documenting procedures, or rolling out iterative upgrades across multiple sites.
Collaboration with OEMs, IT, and Operations
A critical part of the integrator’s role is managing relationships across departments and vendors. This includes coordinating with OEMs to interface with specific machinery, working with IT to ensure compliance and cybersecurity, and engaging with operations to validate workflows and alarms. The best integrators serve as translators between engineering, technology, and business, aligning all parties toward a common outcome.
In some cases, the integrator becomes the de facto project manager for the entire scope, orchestrating timelines, deliverables, and quality control across diverse teams. This coordination is what transforms a series of tools into a complete, functioning system.
Tools, Platforms, and Technologies
Leading PLC Platforms
Programmable Logic Controllers are the foundation of automated manufacturing systems. They are responsible for real-time machine control and are the first layer of logic in almost every production environment. Choosing the right PLC platform impacts scalability, vendor flexibility, and long-term supportability. The most widely used platforms include Allen-Bradley from Rockwell Automation, Siemens S7 series, and Omron. Each has its own programming environment, communication protocols, and support ecosystem.
Allen-Bradley systems are common in North America and are often paired with FactoryTalk software. Siemens is more widely used in Europe and offers powerful integration between hardware and software through its TIA Portal suite. Omron is often found in packaging and discrete automation applications, valued for its compact footprint and reliability. System integrators help standardize on a PLC family or support environments with mixed platforms, depending on the facility’s history and vendor preferences.
If you want to understand how structured PLC logic and data organization impacts performance and integration, Joltek has written about this topic in detail in the article on PLC data structures and SCADA integration.
SCADA and MES Systems
Above the PLC layer, Supervisory Control and Data Acquisition and Manufacturing Execution Systems provide visualization, reporting, and operational control. Integrators work with tools such as Ignition, AVEVA, GE Proficy, Wonderware, and FactoryTalk View to create custom operator interfaces, trends, alarms, and production dashboards. MES solutions may include work order tracking, quality enforcement, recipe management, and downtime analytics.
A well-integrated SCADA or MES platform reduces human error, increases uptime, and provides a shared view of operations across engineering, maintenance, and production teams. The choice of platform often depends on licensing models, ease of use, available connectors, and vendor familiarity. Ignition is known for its flexibility and licensing simplicity. AVEVA and GE Proficy have deep roots in heavy industry and utilities. FactoryTalk pairs well with Rockwell hardware, offering a native integration path.
To explore real-world SCADA challenges and decisions, you can refer to Joltek’s in-depth article on SCADA system architecture.
Historian and Data Platforms
Data historians are purpose-built tools for capturing and storing time-series industrial data. They are essential for long-term analysis, compliance, and advanced analytics. Common platforms include OSIsoft PI, Canary, and InfluxDB. A reliable historian is the difference between guessing and knowing what happened in your plant last week, last year, or during the last critical batch.
System integrators ensure that data is tagged correctly, organized logically, and integrated with other platforms such as business intelligence tools or cloud analytics engines. They also help with redundancy, data compression, and backup strategies. Some modern SCADA systems include embedded historians, but larger operations often benefit from a dedicated platform.
Networking and Security
Networking is the invisible infrastructure that connects machines, control panels, operator terminals, and servers. Integrators design physical and logical networks using industrial switches, firewalls, routers, and access points. This includes configuring VLANs, setting up secure remote access, implementing traffic segmentation, and aligning with IT policies.
A poorly designed network introduces instability, creates security vulnerabilities, and can disrupt production when misconfigured. System integrators provide guidance on network layout, device naming, bandwidth considerations, and cybersecurity best practices. They often work closely with IT to ensure compliance while preserving OT performance and uptime.
Industrial Protocols
Communication protocols are what allow devices to talk to each other. Every integration project requires a deep understanding of industrial protocols and how to apply them reliably. Some of the most common include:
- EtherNet IP for Allen-Bradley systems
- Profinet for Siemens systems
- Modbus TCP for general equipment
- OPC UA for cross-platform data modeling and interoperability
- MQTT for lightweight publish-subscribe communication, often used in Unified Namespace architectures
Choosing the right protocol affects latency, data granularity, and integration complexity. Many systems require protocol converters, gateway devices, or middleware layers to ensure interoperability. Integrators not only select the appropriate protocol but also help configure them with performance and security in mind.
Joltek has previously explored how MQTT is reshaping manufacturing architectures in its post on modern data strategies.
Modern Trends
Unified Namespace
Unified Namespace is an architectural approach that provides a central, real-time view of all industrial data using a structured topic tree, typically over MQTT. It decouples systems, making data easier to access, subscribe to, and use across departments. Instead of connecting each application directly, data flows into a single namespace where any consumer can tap in without disrupting other systems.
This approach supports faster scaling, simplified troubleshooting, and more agile integration with enterprise systems. It is particularly valuable in facilities pursuing digital transformation or building their first data lake.
Edge Computing
Edge computing involves deploying computation and logic close to the source of data. It reduces latency, offloads network bandwidth, and enables real-time decisions without depending on cloud or remote servers. Integrators deploy edge gateways that run analytics, buffer data, and filter noise before sending insights upstream.
Edge strategies are especially useful in remote facilities, high-speed production lines, or applications with strict uptime requirements. These devices often support containerization, remote updates, and machine learning inference.
Cloud Connectors
As more manufacturers adopt cloud services for analytics, reporting, and remote monitoring, system integrators are tasked with implementing cloud connectors that securely transmit data. This might involve Azure IoT Hub, AWS Greengrass, or custom APIs. Security, bandwidth management, and structured data formatting are critical to success in cloud integration.
Integrators help map out what data should be sent to the cloud, how often, and in what structure. They also support encryption, authentication, and alignment with corporate governance policies.
Version Control for Automation Code
Modern system integrators are bringing software engineering practices into industrial environments. This includes using Git repositories to track PLC code changes, SCADA configuration files, and MES scripts. Version control improves collaboration, simplifies rollback during troubleshooting, and enables better handoff between teams.
When implemented correctly, Git allows integrators and internal teams to maintain a clean record of changes, including comments, timestamps, and author attribution. It supports both local and cloud-based repositories and encourages more disciplined development workflows in automation projects.
System Integrator Business Models
Project-Based Contracts
One of the most common ways system integrators operate is through fixed-scope project-based contracts. In this model, the integrator and client agree on a defined scope, deliverables, timeline, and budget before work begins. This structure works best when requirements are well-understood and changes are minimal, such as in repeatable automation projects or upgrades with clear specifications. The advantage is predictability, but the downside is inflexibility. If scope changes midstream, renegotiation may be required, which can create delays and frustration.
Clients often favor this model for capital projects or compliance-driven initiatives where the outcomes are non-negotiable. However, it demands a strong upfront discovery and scoping phase, including clear documentation of Functional and User Requirements, as discussed in the earlier section on how integrators work.
Time and Materials
Another common model is time and materials, where clients pay for the actual hours worked and materials used. This is often used when the scope is evolving or uncertain. Time and materials contracts provide maximum flexibility, allowing teams to adjust quickly as issues or new opportunities emerge. For clients with capable technical leads or evolving environments, this model supports collaborative development and iterative delivery.
However, this model requires trust. Clients must ensure that billing is transparent and that project management disciplines are in place. Integrators must be disciplined in tracking hours, documenting progress, and aligning frequently with stakeholders. When handled correctly, time and materials can be a powerful structure for innovation and agility.
Support Retainers and Service Level Agreements
Support retainers and service level agreements allow manufacturers to engage integrators for ongoing maintenance, troubleshooting, or optimization work. This is especially useful after a major deployment when internal teams need backup or expertise. A well-structured SLA defines response times, availability, escalation procedures, and ownership boundaries, giving clients peace of mind and reducing operational risk.
Some SLAs also include continuous improvement efforts, like monthly reviews or small system enhancements. These arrangements benefit plants with limited internal technical capacity or those undergoing frequent changes in production requirements.
Staff Augmentation versus Consulting Engagements
System integrators sometimes provide personnel directly to supplement internal engineering teams. This staff augmentation model gives clients access to skilled automation professionals without hiring full-time. This is ideal for short-term surges in workload, commissioning periods, or bridging a gap while hiring. The integrator remains the employer, while the client oversees daily activities.
In contrast, consulting engagements are more strategic. Here, the integrator is brought in to provide guidance, conduct assessments, or define architecture, rather than execute predefined tasks. At Joltek, for example, much of the value we bring in consulting is helping clients think through modernization roadmaps, IT and OT alignment, or vendor selection decisions that set the course for the next five years.
White Labeling for OEMs or Software Vendors
Some integrators work behind the scenes, delivering services on behalf of original equipment manufacturers or software companies. This white-label model allows OEMs to scale deployments or support without building an internal integration team. The integrator delivers the work, but under the brand of the OEM or vendor, maintaining consistent customer experience while increasing delivery capacity.
This model requires tight alignment between the integrator and the lead brand. Documentation standards, technical architecture, and customer service expectations must be harmonized to avoid confusion. For integrators, this can be a high-volume and stable source of work, especially when OEMs need support across large geographies.
Building Long-Term Strategic Partnerships
Beyond contracts, the most forward-thinking system integrators aim to build strategic partnerships. In these relationships, the integrator becomes a trusted advisor, helping the client navigate technological change, workforce development, and system evolution. This model prioritizes long-term outcomes over short-term transactions, enabling better planning, stronger alignment, and higher return on investment.
Strategic partnerships often begin with a small engagement or pilot project and grow into multi-year collaboration. They may include shared KPIs, technology roadmaps, co-developed standards, or site-specific playbooks. At this level, integrators are not just technical contributors. They become part of the operational fabric of the organization.
Evaluating and Selecting a System Integrator
Technical Capability Versus Domain Expertise
When choosing a system integrator, many manufacturers begin by looking at technical certifications and tools. While this is important, domain expertise is often a stronger predictor of success. An integrator might be highly skilled in a specific platform, but if they do not understand your industry’s standards, workflows, or regulatory constraints, the result may fall short. For example, an integrator used to working in high-speed bottling lines may struggle to implement a compliant batch process in pharmaceutical manufacturing.
On the other hand, someone with strong domain expertise can often pick up a new tool quickly. What they bring to the table is a deep understanding of your operations, typical failure modes, user needs, and compliance expectations. The most successful projects often involve teams that blend both qualities. Integrators who ask about your pain points, production goals, and long-term roadmap during the proposal stage are more likely to deliver lasting results.
Certifications and Affiliations
Certifications can provide a baseline indication of quality, capability, and vendor relationships. Many manufacturers look for integrators who are certified with specific hardware or software vendors. These may include:
- Rockwell Automation Recognized System Integrators
- Siemens Solution Partners
- Inductive Automation Premier Integrators
- AVEVA Certified Partners
- Certified CSIA Members (Control System Integrators Association)
These credentials show that the integrator has completed technical training, maintains good standing with the vendor, and adheres to development best practices. While certifications should never be the only factor in your decision, they offer reassurance that the partner you choose has experience working within vendor ecosystems and can escalate issues if needed.
Past Work and Reference Projects
The most useful insights often come from reviewing an integrator’s past work. Ask for project summaries, system architectures, or sample code from completed implementations. Even better, request a reference call with a previous client. Real-world experience in similar environments provides confidence that the integrator understands your operational realities.
When reviewing case studies or reference projects, pay attention to the following:
- Was the project delivered on time and within budget?
- What was the scope of technologies deployed?
- How did the integrator support the team after commissioning?
- What challenges came up and how were they resolved?
You want to understand not just what was delivered, but how the integrator behaves under pressure, handles change, and communicates across departments.
Alignment with Your Internal Team
The best integrations happen when the external team works as an extension of your internal staff. This goes beyond technical skills. Cultural alignment, communication style, and project management approach all impact whether the project succeeds smoothly or becomes a series of misunderstandings.
During early conversations, assess how the integrator collaborates. Do they take time to understand your workflows? Do they engage with operators and supervisors, not just managers? Are they transparent about tradeoffs and honest about limitations? These soft skills are often overlooked but play a critical role in system adoption and long-term success.
Key RFP and Vendor Assessment Tips
If you are issuing a Request for Proposal, keep it focused on outcomes rather than technical checklists. A long list of platform knowledge does not guarantee a good fit. Instead, describe the problem you are trying to solve, the constraints you face, and the value you hope to unlock. Then evaluate responses based on how clearly the integrator understands the context, offers realistic solutions, and articulates how they will support you through uncertainty.
Here are a few things to include in your evaluation process:
- Ask for a sample project plan or delivery methodology
- Request a short technical proposal or concept sketch
- Include interview questions for team leads, not just salespeople
- Assess their documentation practices and version control strategy
- Confirm availability during key commissioning windows
RFPs should reveal whether the integrator is just responding with a template or actually thinking through your problem with care and creativity.
Red Flags to Watch Out For
Not all integrators are created equal. There are several warning signs to pay attention to during the selection process. These include:
- Vague or boilerplate proposals with little relevance to your plant
- Resistance to collaboration or transparency
- Poor documentation habits or lack of version control
- Heavy reliance on one person with no backup
- No ownership after commissioning or refusal to train your staff
- High turnover or inconsistent team assignments
- Unwillingness to discuss previous project failures
A good integrator should be comfortable discussing past mistakes and lessons learned, not just successes. This shows maturity and willingness to grow alongside your team.
Selecting the right system integrator is not just about who can build your system. It is about who can help you operate and evolve that system over time. If you are currently evaluating vendors or preparing an RFP, consider reviewing Joltek’s plant modernization framework which outlines how strategic planning and integrator alignment impact long-term success.
Challenges and Risks in System Integration
Misaligned Expectations
One of the most common sources of failure in integration projects is a mismatch between what the client expects and what the integrator delivers. This often begins in the early conversations when goals are assumed but never written down. Misaligned expectations lead to disappointment, missed timelines, and blame shifting. Clients may assume the integrator will provide long-term support, operator training, or enterprise integration, while the integrator assumes the project ends at commissioning.
This is why discovery, documentation, and early clarification of responsibilities are critical. Integrators should not only ask about technical requirements but also the business context, handoff expectations, and internal resource availability. Clients should ensure that goals are clearly defined and validated by the people who will use and maintain the system.
Scope Creep and Poor Requirements Definition
Scope creep is a silent killer of timelines and budgets. It happens when new tasks are added mid-project without revisiting the original constraints. Often, the root cause is not a change in need, but a lack of clear requirements in the first place. Without a well-defined Functional Specification Document, even simple requests can unravel carefully built systems.
Integrators must learn to say no to undocumented changes and insist on formal change control. Clients, on their end, must dedicate time to develop detailed requirements up front, with input from operators, engineers, and maintenance. When done well, this creates a shared baseline that allows teams to manage change rather than react to it.
To help structure this process, Joltek explores best practices in early planning and modernization scoping in our article on legacy systems and risk management, which provides guidance on assessing risk before integration begins.
Vendor Lock-In and Lack of Documentation
A poorly documented system becomes a long-term liability. Many plants find themselves stuck with systems that no one fully understands because the original integrator never handed over clean code, tagged I O maps, or architecture drawings. Vendor lock-in occurs when only the original team can safely make changes, creating dependency and increasing long-term cost.
Clients should demand that integrators provide full project documentation before final payment. This includes network diagrams, PLC source code, SCADA project backups, software licenses, and update procedures. Better yet, include documentation milestones in the contract itself. Internally, the plant should create a habit of version control and train staff to interpret and maintain the systems delivered.
Cybersecurity Vulnerabilities
Industrial systems are increasingly connected to enterprise networks and cloud services. Unfortunately, many integration projects still ignore basic cybersecurity hygiene. Systems are deployed with default passwords, flat networks, and open ports. Cybersecurity is not just an IT issue. In manufacturing, it directly impacts safety, uptime, and data integrity.
Integrators must understand how to design segmented networks, secure remote access, and implement role-based authentication. Clients should involve IT early, define access policies, and insist on security validation during commissioning. Shared responsibility is essential because no integrator can secure a system alone. Policies, culture, and training all matter.
For more insight on this, you can explore Joltek’s article on secure SCADA and industrial architecture, which touches on practical security features across real deployments.
Poor Commissioning and Lack of Ownership from the Client
Even with great design, systems fail if commissioning is rushed. Commissioning is where the system meets the real world, and many bugs, misconfigurations, or training gaps surface. Poor commissioning often stems from lack of time, limited access to the right people, or absence of structured testing plans. This is where ownership needs to shift from the integrator to the plant team.
Clients should assign dedicated staff to shadow commissioning, document exceptions, and begin owning the system from day one. Integrators should provide structured FAT and SAT processes, punch lists, and sign-off protocols. When both sides treat commissioning as a phase, not a task, the result is smoother adoption and better long-term outcomes.
Managing Lifecycle Support and Change Management
Technology evolves, operations shift, and staff turn over. If the system delivered is not supported or adaptable, it slowly becomes obsolete. Lifecycle support is not just about having someone to call when something breaks. It is about evolving with the plant and managing controlled change over time.
Good integrators offer service packages, change request processes, and ongoing improvement support. Even better, they train internal teams and build systems that can be understood and modified by plant personnel. Clients must invest in documentation, backups, version tracking, and skills development to stay in control as their systems evolve.
Future of System Integration
Standardization versus Customization
The future of system integration is increasingly defined by the tension between standardization and customization. Manufacturers want flexible systems, but they also need maintainability and ease of scaling. Standardization helps reduce complexity, lower costs, and accelerate deployment across multiple facilities, but too much standardization can lead to rigid systems that cannot accommodate unique operational needs.
The best integrators of the future will not choose one side. They will learn to build standardized frameworks with configurable elements. This includes using reusable code libraries, modular network designs, and template-driven SCADA interfaces that still leave room for plant-specific logic. Integrators will be expected to balance repeatability with the nuance of each plant’s reality.
Rise of Platform-Based Integration
Low-code and no-code platforms are gaining traction in manufacturing, allowing integrators and even internal teams to develop applications, dashboards, and logic without traditional programming. Tools like Ignition Perspective, Node-RED, and various cloud-native builders are changing how systems are deployed. Platform-based integration enables faster prototyping, easier iteration, and broader collaboration across technical levels.
This shift does not eliminate the role of the integrator. It redefines it. Future integrators will need to curate the right platforms, enforce architecture discipline, and guide internal teams on how to scale responsibly. The value will not be in writing every line of code, but in setting up governance, templates, and data models that others can build upon.
For a closer look at platform-driven integration and data layer planning, you can explore Joltek’s article on industrial data integration, which outlines how architectures can be built for both flexibility and control.
AI-Powered Troubleshooting and Predictive Maintenance
Artificial intelligence is moving from concept to tool on the plant floor. AI models are now being used to identify process anomalies, predict machine failures, and optimize energy usage. This has deep implications for system integration. Integrators will need to incorporate AI into their architectures, not just as an add-on, but as a core component of system design.
This includes creating data pipelines that support training and inference, deploying edge compute for real-time decision-making, and ensuring data quality at the source. Future integrators will collaborate with data scientists and reliability engineers, helping close the gap between control systems and advanced analytics. AI is not replacing integrators. It is elevating the type of value they are expected to deliver.
Increasing Demand for IT and OT Convergence Specialists
The historical divide between IT and OT is no longer sustainable. As more systems connect to the cloud, integrate with ERP, and rely on secure remote access, integrators must bridge both worlds. The most valuable integrators in the future will not just understand PLCs or databases. They will understand the entire technology stack and how it fits within the business strategy.
This includes working with Active Directory, VLAN configurations, OPC UA models, MQTT brokers, and even REST APIs that connect to cloud services. Integrators who can communicate fluently with both the maintenance team and the corporate CIO will be in high demand. Their job will not be to replace either team, but to align them through architecture and execution.
Joltek dives deeper into this challenge in our piece on SCADA system architecture, which highlights how systems must be designed with both OT needs and IT governance in mind.
The Integrator as Strategic Advisor
Historically, integrators have been viewed as implementers. They build what the client specifies. That is changing. Forward-looking integrators are becoming strategic advisors who help define the roadmap, identify gaps, and shape how technology investments align with business outcomes. They participate in capital planning, vendor selection, and digital transformation strategies.
This new role requires credibility, communication skills, and the ability to frame technical recommendations in the language of business. Integrators must explain how a control upgrade supports uptime goals, how MES enables better margin analysis, or how version control improves audit readiness. The integrator of the future is not just a doer. They are a guide.
Startups and Niche Players Disrupting the Market
Innovation in system integration is no longer coming only from the traditional players. Startups are entering the market with specialized offerings, from cloud-native MES platforms to preconfigured data pipelines for machine learning. These companies often move faster, take more risks, and target underserved gaps in integration workflows. Niche players are changing expectations around cost, speed, and openness.
For established integrators, this means adopting startup tools, adapting startup thinking, or partnering with newer vendors who bring a different approach. For clients, it means having more options and needing better criteria for evaluating who to trust. The future of integration will be shaped by both experience and experimentation.
Joltek’s Approach to System Integration
How Joltek Differs from Traditional Integrators
Joltek approaches system integration from a fundamentally different perspective than many traditional firms. While most integrators focus strictly on technical delivery, Joltek blends engineering execution with strategic foresight and operational impact. Our roots in manufacturing and our deep understanding of both plant-floor realities and corporate objectives allow us to deliver systems that not only work technically, but also make sense for the business.
We do not treat integration as a one-time task. We treat it as a long-term partnership. Our projects are designed for ownership, not dependence. We aim to empower client teams through documentation, training, and flexible architectures that support internal growth rather than vendor lock-in. Clients often bring us in when their previous systems have become too rigid, unsupported, or disconnected from current business goals.
Use Cases and Outcomes from Past Projects
Joltek has worked with a wide range of manufacturers across North America, including food and beverage, life sciences, and consumer goods. These engagements have ranged from targeted controls upgrades to multi-site modernization programs. Our success comes from being hands-on with the systems while staying aligned with executive-level expectations.
In one case, we supported the design and rollout of a new SCADA architecture across multiple plants for a major food manufacturer. The project involved migrating away from legacy platforms, creating a unified namespace for data integration, and aligning operators, IT, and engineering around a shared set of dashboards and workflows. The result was faster troubleshooting, reduced downtime, and a system that the internal team could confidently maintain.
For a breakdown of how we approach plant upgrades, see our piece on modernizing legacy systems, which outlines the risks, costs, and process for replacing outdated infrastructure with scalable architecture.
Emphasis on Digital Transformation, Sustainability, and Scalability
Digital transformation is not just a buzzword. At Joltek, we see it as the structured process of turning disconnected, outdated systems into a cohesive operational platform that drives improvement across safety, quality, efficiency, and resilience. Sustainability and scalability are built into every project, whether we are replacing a single PLC or advising on enterprise-wide MES architecture.
We design systems that grow with your business. This means supporting version control, integrating with cloud platforms when appropriate, and designing modular structures that allow future lines, sensors, or sites to be added with minimal disruption. Our focus is not just to solve the problem at hand but to position your team for long-term success.
Bridging the IT and OT Gap with Engineering and Business Expertise
What truly sets Joltek apart is our ability to operate comfortably at the intersection of IT and OT. We understand firewalls, VLANs, data models, and cloud APIs, but we also know how to troubleshoot a sensor, tune a PID loop, or validate a changeover sequence on a packaging line. This dual fluency means we can bridge gaps that others struggle to close.
Our background includes not only controls and software, but also business strategy and operations leadership. This allows us to translate technical decisions into business impact and to help clients align their technical investments with plant and corporate KPIs. Integration is no longer just an engineering challenge. It is a business decision. Joltek is designed to meet that reality head-on.
Conclusion
Recap of Key Insights
System integration is no longer just about wiring control panels or installing SCADA software. It is about building intelligent, connected, and flexible systems that support your operational and strategic goals. The best integrators combine technical expertise with business understanding, align with your internal teams, and plan for both today and tomorrow.
Throughout this article, we have explored what system integrators do, how they work, why you need them, how to evaluate them, and what trends will define the future. We have also shared Joltek’s unique approach, shaped by years of experience in complex manufacturing environments and grounded in real-world results.
Final Thoughts for Decision-Makers
If you are leading a plant, overseeing engineering, or driving transformation at the enterprise level, system integration should be seen not as a commodity, but as a strategic capability. Your systems are the foundation of your production, your compliance, your efficiency, and your innovation. The partner you choose to design and support those systems matters more than ever.
Do not settle for a short-term fix or the cheapest bidder. Look for alignment. Look for clarity. Look for a team that not only understands your technology, but also respects your people and your goals.
What to Do Next
- Assess your integration needs by reviewing your current architecture, operational pain points, and digital ambitions
- Download our free project scoping template to help define your goals, constraints, and requirements
- Contact Joltek for a discovery call and start a conversation about how we can help you build smarter, more resilient systems
Let’s build something that works today and scales into the future.
