IoT integration into legacy systems (OT/IT)
Connect your existing equipment and core systems to real-time data and automation, while maintaining stability and modernizing around it.
When IoT integration with legacy systems is the right choice
Integrating IoT into your existing legacy system is a good fit if you recognize these situations:
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Ready to scale? Let’s discuss your legacy setup and build a custom IoT bridge today.
What we integrate
We connect the parts you already have for clean data flow.
Operational technology
PLCs, sensors, machines, gateways, industrial networks: we collect signals from legacy and mixed-vendor equipment without changing how it runs.
Integration layer
Protocol translation, normalization, buffering, rules, edge computing: this layer turns device chatter into stable, versioned data your systems can trust.
IT and cloud
ERP, MES, SCADA, CMMS, data warehouse, BI, data lake, alerting, ticketing: we deliver telemetry and events where they drive actions, e.g., reports, maintenance, and operations.
For 14+ years, we have proudly taken responsibility for your IoT projects!
Built for legacy environments
Legacy IoT projects fail on predictable points: protocol gaps, security boundaries, and data volume. We design around these constraints and keep the core system stable.
Integration that stays maintainable
You get a connector layer with clear interfaces, documented mappings, and version control, so the integration can evolve without breaking production.
Production-safe delivery
We work in stages: discovery, blueprint, pilot, scale, and operations. Each step has acceptance criteria and a rollback path. Monitoring is part of the initial release.
IoT is a core service line
IoT development is a dedicated service area at SumatoSoft, with related offerings like IoT security and compliance.
Digital transformation doesn’t require tearing down the foundations of your success. By integrating IoT into legacy systems, we aren’t just ‘plugging in’ hardware; we are unlocking decades of trapped data and turning silent machinery into an intelligent, communicative ecosystem. It’s the most cost-effective way to bridge the gap between industrial reliability and modern agility.
Awards & Recognitions
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Benefits of IoT integration in legacy systems
Modernization without ripping out what still works
Legacy systems often stay in place for a reason. They run critical processes and have years of proven stability. IoT integration lets you add new data flows and automation around the core system while keeping its logic intact.
It’s not a multi-million rip-and-replace project
Replacing an industrial control system, a plant-wide SCADA stack, or a core back-office platform can take years and force long production stops. Integration gives you a smaller, controlled scope. You extend asset life and protect prior investment instead of restarting from zero.
Blind assets become measurable
Many older machines expose only basic signals or require manual checks. IoT integration adds continuous telemetry and events: machine health, energy use, throughput, and anomalies. Once the data is available, teams can act on it fast.
Fast operational wins from new data
Real-time visibility opens practical improvements that were impossible before. Predictive maintenance becomes realistic. Downtime analysis gets cleaner. Energy spikes stop being a mystery and start being actionable.
Compliance and reliability are kept with minimal disruption
In regulated environments, the legacy system can be part of an audited process. Full replacement adds validation risk and can break established controls. Integration lets you modernize monitoring and reporting on the periphery while preserving the proven system of record.
Integration fragility is reduced over time
A structured integration layer replaces ad-hoc “translator per device” setups. You get a consistent data model, versioned connectors, monitoring, and clear ownership boundaries. The result is a system you can change safely as the estate grows.
Security and reliability of legacy IoT integrations
SumatoSoft ensures that IoT security and reliability measures are built in from day one.
- Network segmentation and least-privilege access
- Device identity, certificates or keys, secure update strategy when relevant
- Encryption in transit and audit logs
- Monitoring, retries, and buffering for unstable links
- Backward-compatible changes, rollback plans, testing in staging, or a digital twin when available
Our recent works
The system has produced a significant competitive advantage in the industry thanks to SumatoSoft’s well-thought opinions.
They shouldered the burden of constantly updating a project management tool with a high level of detail and were committed to producing the best possible solution.
I was impressed by SumatoSoft’s prices, especially for the project I wanted to do and in comparison to the quotes I received from a lot of other companies.
Also, their communication skills were great; it never felt like a long-distance project. It felt like SumatoSoft was working next door because their project manager was always keeping me updated. Initially.
We tried another company that one of our partners had used but they didn’t work out. I feel that SumatoSoft does a better investigation of what we’re asking for. They tell us how they plan to do a task and ask if that works for us. We chose them because their method worked with us.
SumatoSoft is great in every regard including costs, professionalism, transparency, and willingness to guide. I think they were great advisors early on when we weren’t ready with a fully fleshed idea that could go to market.
They know the business and startup scene as well globally.
SumatoSoft is the firm to work with if you want to keep up to high standards. The professional workflows they stick to result in exceptional quality.
Important, they help you think with the business logic of your application and they don’t blindly follow what you are saying. Which is super important. Overall, great skills, good communication, and happy with the results so far.
They are very sharp and have a high-quality team. I expect quality from people, and they have the kind of team I can work with. They were upfront about everything that needed to be done.
I appreciated that the cost of the project turned out to be smaller than what we expected because they made some very good suggestions. They are very pleasant to work with.
The Rivalfox had the pleasure to work with SumatoSoft in building out core portions of our product, and the results really couldn’t have been better.
SumatoSoft provided us with engineering expertise, enthusiasm and great people that were focused on creating quality features quickly.
SumatoSoft succeeded in building a more manageable solution that is much easier to maintain.
When looking for a strategic IT-partner for the development of a corporate ERP solution, we chose SumatoSoft. The company proved itself a reliable provider of IT services.
Thanks to SumatoSoft can-do attitude, amazing work ethic and willingness to tackle client’s problems as their own, they’ve become an integral part of our team. We’ve been truly impressed with their professionalism and performance and continue to work with a team on developing new applications.
We are completely satisfied with the results of our cooperation and will be happy to recommend SumatoSoft as a reliable and competent partner for development of web-based solutions
Together with the team, we have turned the MVP version of the service into a modern full-featured platform for online marketers. We are very satisfied with the work the SumatoSoft team has performed, and we would like to highlight the high level of technical expertise, coherence and efficiency of communication and flexibility in work.
We can say with confidence that SumatoSoft has realized all our ideas into practice.
Integration patterns
These are common setups we implement. Each one solves a specific bottleneck.
- Legacy machine → gateway → MQTT/HTTPS → cloud/analytics
You keep the machine controls intact. The gateway publishes normalized telemetry.
As a result, you get real-time monitoring and analytics without interfering with the PLC logic.
- SCADA historian → event stream → data warehouse
We extract historical signals and convert them into a stream and curated tables.
As a result, plant data becomes usable for BI, trends, and cross-site reporting.
- MES/ERP sync for production + maintenance context
We align orders, shifts, batches, and asset metadata with operational events.
As a result, downtime and quality issues get a business context, and you can act on them.
- Condition monitoring → CMMS work orders
Sensors or existing signals trigger rules and maintenance workflows.
As a result, you get earlier detection of issues with devices and fewer maintenance surprises.
- Asset tracking → inventory/warehouse system
Tags and readers feed location and state changes into inventory logic.
As a result, the network loses fewer assets, audits faster, and gets a clearer chain of custody.
- Edge rules → alerts → ticketing (ServiceNow, Jira, and more)
We evaluate thresholds and anomalies at the edge or in the pipeline.
As a result, you receive actionable alerts with routing, deduplication, and traceability.
Optimize your operations
Connect your legacy assets to a modern dashboard and start reducing downtime immediately.
Results of integrating IoT with your legacy solution
After we implement your legacy system with IoT, you get the following artifacts that you own and maintain:
- Integration architecture and data flow map
- Protocol and connector layer (drivers, adapters)
- Canonical data model and mappings
- Pipelines (edge or cloud) and storage schema
- Monitoring dashboards and alerts
- Runbooks and handover documentation
SumatoSoft rolls out IoT integration without disrupting production
We inventory the systems, map protocols, data owners, network zones, and operational constraints, and define what cannot change.
We design a canonical data model and mappings from each source system, define latency targets, data frequency, retention, and SLAs, and decide where processing happens: on the edge, on-prem, or in a cloud.
We start small to prove two things: value and stability. The pilot validates data quality, integration behavior under load, and production safety.
We convert what worked into templates and repeatable patterns, version connectors and mappings, add monitoring coverage, and set change control rules for releases.
We set up observability, incident response, and update procedures. The integration stays maintainable as systems, vendors, and requirements change.
What changes when the IoT integration is in place
Unified telemetry across sites and vendors
Faster root-cause analysis with fewer blind spots
Automated maintenance triggers and cleaner work orders
Data you can trust for analytics and forecasting
Let’s start
If you have any questions, email us info@sumatosoft.com
Frequently asked questions
Do we need to replace equipment when integrating IoT with our legacy system?
No. The goal is to integrate around what still works. We add gateways, sensors, or connectors where needed.
How do you handle proprietary protocols when integrating IoT?
We use available drivers when they exist. When they don’t, we build adapters and document the interface and mappings.
Can you work with air-gapped networks?
Yes. We can design on-prem or segmented deployments that keep the core isolated and control what crosses boundaries.
What’s a typical pilot timeline?
A pilot for legacy IoT integration usually takes 8–12 weeks end-to-end.
How do you monitor integrations in production?
We implement logs, metrics, health checks, and alerting. You can see connector status, data latency, error rates, and retries. We can also develop a data analysis solution for you.
