Building a network for industrial purposes

In this article, we describe how we built a reliable network for industrial purposes, tailored to modern requirements. We combined two separate projects, where we used the same approach and identical devices. The sites were a manufacturing facility and a warehouse, both of which required stable connectivity, wireless signal coverage, and decent capacity.
For security reasons, we have decided to only share information that is not confidential to our clients.

How we built a reliable network in an industrial base: from theory to implementation

Building a stable and efficient network in a warehouse and production environment is a challenge that requires serious preliminary preparation. No “default” network works well in a hall with high ceilings, metal structures, and dynamically moving people and machines. That is why we approached each step of both projects in detail.

First step: planning with an eye on real needs

First of all, we conducted a study on how such solutions are implemented, what are the recommendations of specialists who have already implemented such networks, and what possible problems may arise. The goal was to do precise planning in advance so that we could determine exactly where to place the wireless connectivity points so that the signal covers the entire area of the premises, without any blind spots, signal interference, or other disturbances.

Additionally, we collected complete information from customers about all types of devices that would use the network. This included desktops, laptops, printers, mobile scanners, IoT modules, machines, IP cameras, and employees’ personal devices. Each group of devices had different requirements and functions. Some of the devices required access to an internal server with local or VPN connectivity, others only to the Internet. Some had to be isolated from the rest of the network – for example, IoT devices or IP cameras. This required planning logical segmentation using VLANs.

We have divided the devices into network groups, according to their function:

• Administration and server infrastructure (access to all internal resources)
• Manufacturing machines and industrial IoT devices (isolated, with limited access)
• Mobile scanners and tablets (access to cloud infrastructure via the Internet)
• Cameras and video surveillance (separate network for security systems)
• And several separate WiFi networks

This way we simultaneously ensured stability, optimal use of network resources and the ability to impose cybersecurity measures.

Example network topology:

From theory to the real environment

We realized that even if we have experience with wired and wireless networks, in an industrial environment we cannot fully trust previous experience or “intuition”. Therefore, we used two specialized software that allowed us to create a digital model of the building, in which we introduced real parameters: room dimensions, static objects, materials (concrete, metal), ceiling heights, position of racks and industrial machines.

Through these simulations:

• We have determined the optimal location for placing each wireless network point (Access Points)
• We analyzed how metal racks, forklifts, and manufacturing machinery would affect signal dispersion.
• We checked the effect of placing the dots
• We calculated the tilt of the directional antennas for maximum coverage
• We evaluated the actual speed and capacity at peak load

The software provided us with a heatmap visualization and an accurate assessment of where the signal would be weak, even before we had laid a single cable.

Why? we didn't use standard AP and Mesh?

In typical office buildings, standard wireless connectivity points, “dishes” (Omni AP) or Mesh systems, are often used. However, in our case, they turned out to be unsuitable. Omni APs scatter the signal in all directions and when installed at a height of 6 to 10 meters, the signal is too weak – especially in the presence of metal structures and racks that absorb and reflect it.

Mesh solutions are also not effective in closed environments with many obstacles, although they are easy to install - they require direct line of sight between devices and have limited communication capabilities.

The solution – directional antennas

Simulations and real-world tests have confirmed that devices with WiFi 6 or WiFi 7 support are a better choice, as they handle multiple clients better and have improved modulation over previous standards, provide error correction, and lower latency.

View of a warehouse with racks arranged lengthwise.
APs (wireless network points) are placed at the end of the room, facing the corridors.

We chose UniFi U7 Outdoor – directional access points suitable for environments such as industrial halls and open areas.

They offer:

• Beam angle:90° for 2.4 GHz and 45° for 5 GHz, which allows focusing the signal to the work area
• Support forWiFi 7, with backward compatibility to WiFi 6/6E/5
• Maximum speed up to 9.6 Gbps, suitable for heavy traffic and real-time streaming
• Support for modern technologies such asMU-MIMO, OFDMA, 4096-QAM and TWTthat optimize traffic for a large number of connected devices

These access points are distinguished not only by technical characteristics, but also by reliability in real operation.

We installed them at about 4 meters high, and an optimal aiming angle was calculated for each point. This provided full and even coverage, with minimum number of devices, no blind areas and no unnecessary overlap, which often leads to interference.

Pre-laid structured cabling allowed for flexibility – each point could be easily moved or adjusted as needed, without disrupting the overall logic of the network.

Wireless infrastructure management via UniFi controller

To provide centralized management and full control over all wireless connectivity points, we installed a UniFi controller - a platform that allows for setup, monitoring, and optimization of the entire WiFi infrastructure from one place.

Through the controller, we were able to easily manage all the parameters of the wireless network:

• Creating and configuring SSID, with different access policies
• Setting up frequencies, channels and signal strength according to the real situation
• Management of roaming behavior between points (seamless roaming)
• Separation of guest networks and VLANs, with full segmentation
• Centralized change of passwords and security policies
• Live monitoring: we see which clients are connected, load at each point, signal strength, speeds and errors
• Logs and statistics for consumption, coverage and interference analysis
• Automatic updates and notifications for problems or dropped devices

Wireframe and network logic

Building a reliable network in an industrial environment requires careful planning of the wired infrastructure. For this purpose, communication cabinets were installed, in which we placed both passive and active equipment.

CAT6 and CAT7 cables were used for maximum speed and interference protection, along with shielded keystone connectors. For the organization of the wiring, we implemented patch panels and arrangement panels, ensuring easy maintenance and future expansion.

The power supply of the wireless points was solved through separate PoE adapters, which gives greater flexibility in servicing and replacement. The active part of the network included Mikrotik switches and routers, chosen for their stability and manageability, as well as the UniFi controller for centralized management of the wireless infrastructure.

Mikrotik devices were chosen because they support VLAN segmentation, Link Aggregation, PoE passthrough, as well as monitoring, technologies that have come into use, as well as for the unparalleled price/quality/functionality ratio. This allowed us to build not just connectivity, but a controlled, scalable and secure network structure suitable for an industrial environment. The APs were powered by separate PoE adapters - easier to replace and more affordable for a larger number of points.

Test and expected result

Once the physical and logical structure of the network was built, we moved on to the final and one of the most important stages – testing, tuning and validating real-world performance. We conducted tests with a variety of devices – mobile scanners, tablets, laptops and phones – measuring coverage, signal strength, latency and the ability of devices to seamlessly move from one access point to another (roaming).

In the logical part, we activated all VLANs and tested the functional isolation between devices – cameras, IoT modules, administrative stations, and industrial machines operated in separate segments without affecting each other. This ensured not only stability, but also a high level of security and control.

Building an industrial network It is not just a matter of installing wireless connectivity points and switches. It is a process that combines engineering logic, adaptability to real conditions, and technological precision.