The Internet of Things has transformed the traditional assembly lines of manufacturing and industrial operations into data-driven powerhouses of precision and efficiency. Organizations worldwide are developing and deploying connected solutions that their customers rely on for mission-critical operations. But device manufacturers confront an essential product development challenge: how do you ensure the longevity of your products when network technology evolves faster than industrial equipment lifecycles?
For manufacturers of IIoT (Industrial Internet of Things) devices, network sunsets can be costly. When cellular carriers phase out older networks, manufacturers can find themselves facing expensive hardware redesigns to maintain compatibility. Today, we’re exploring how to harmonize your product development with evolving network technologies to protect your engineering investment and deliver seamless experiences for your customers.
Understanding Network Sunsets
Network sunsets occur when cellular carriers shut down older network technologies. This frees up spectrum for newer, more efficient networks. Common reasons include:
- Advancing technology (e.g. 5G replacing 4G)
- Reallocating spectrum to increase network capacity
- Reducing costs of maintaining legacy networks
As cellular carriers phase out older networks to make way for new technologies, manufacturers must redesign their hardware to support newer protocols—a process that can take months of engineering time and significant capital investment.
The sunset of 2G and 3G systems continues to send aftershocks. A few European cellular carriers stopped supporting these connections in 2021 with U.S. carriers following suit in 2022, and the majority of European carriers plan to decommission 2G and 3G connections in 2025. If not addressed, mission-critical systems will lose their connection, leaving your business to foot the bill to replace or upgrade your IIoT hardware.
The Product Design Challenge
For device manufacturers, there’s a fundamental mismatch between product design cycles and network evolution. Your team designs industrial equipment for long-term operation, while cellular networks change approximately every decade.
| Average Lifespan of Industrial Equipment by Vertical | |
| Transport Equipment | ~6 years |
| Computers | ~9 years |
| Industrial Machinery | ~26 years |
| Industrial Electronics | Between 5-15 years |
For example, when developing products for industries like agriculture, where equipment typically operates for 10-15 years, manufacturers must consider how to maintain connectivity as networks evolve. Traditional approaches often require complete hardware redesigns to support new protocols—a costly and time-consuming process.
Future-Proofing Your IIoT Devices
Advances in network technology don’t have to mean costly upgrades to your equipment’s hardware. At Blues, we’re leading the industry in developing wireless connectivity for smart manufacturing. When American Crane & Equipment Corporation wanted to future-proof its IIoT equipment, it turned to Blues to ensure consistent network connectivity.
“We expect a 10X factor in cost savings for our smart crane system,” said Karen Norheim, ACECO President and CEO. “Through innovation in transmitting data, using the Blues system will provide lower up-front and ongoing costs than a traditional system.”
Solutions for Every Connectivity Challenge
At Blues, we understand the engineering and cost implications of network sunsets. That’s why we’ve developed flexible solutions that help manufacturers future-proof their products while minimizing redesign costs.
Challenge: Your IIoT devices rely on a single connectivity source
Solution: Your IIoT equipment is vulnerable to a network sunset if it only supports one connectivity option. Blues Notecards feature interchangeable radio access technologies that combine prepaid cellular connectivity, low-power design, and secure “off-the-internet” communications in one System-on-Module. These devices support multiple connectivity options including cellular, WiFi, LoRa, and Satellite connections. If one system becomes obsolete in the future, you have the flexibility to switch with minimal changes to your equipment’s hardware or software.
Challenge: Upgrading IIoT Hardware is Expensive and Time-Consuming
Solution: Notecard is designed with upgrade features that can be executed in the field, saving your organization time and resources. They’re also designed to be swapped out without redesigning host hardware. Blues also offers OTA updates for Notecards and host firmware, meaning you’re able to adapt your network tech without replacing entire devices.
Challenge: Your IIoT systems rely on different connectivity sources.
Solution: At Blues, we’re pioneering wireless harmonization. We empower our customers to seamlessly apply a single connectivity solution to multiple technologies with minimal design or software changes. Our products use a consistent API across all connectivity types, simplifying development and maintenance of your infrastructure as you adapt to network changes.
Challenge: Your systems are tied to specific carriers and your coverage is inconsistent globally.
Solution: With Notecard’s embedded Sim, you get global cellular connectivity coverage in over 135 countries worldwide. For areas without coverage, you are able to use an external sim alongside the Notecard to ensure global coverage, giving you flexibility to choose the best available network as the wireless landscape shifts.
Challenge: Your organization needs long-term cost and operational stability
Solution: Cellular carriers continue to evolve their networks faster than the lifespan of most IIoT devices, creating a heavy and unpredictable burden for businesses. We provide our customers with 10 years of service and use a pre-paid data model that eliminates ongoing costs. Plus, our global coverage solutions give peace of mind against short-term network changes disrupting your devices.
Building for Tomorrow’s Networks Today
Network sunsets don’t have to pose a threat to your business. Blues offers flexible, upgradable products and features to harmonize your industrial IoT infrastructure including:
- Interchangeable connectivity options
- Easy field upgrades
- Consistent development experience
- Carrier-agnostic global coverage
- Long-term connectivity assurance
- Extended device lifespans
Ready to learn how Blues can help future-proof the IIoT technology your business relies on? Contact us today to get started.