Cost of Setting Up Remote PLC Access System – Complete Industrial Setup Guide
Cost of Setting Up a Remote PLC Access System
Remote PLC access systems allow engineers to connect to industrial machines from remote locations for diagnostics, troubleshooting, monitoring, and maintenance. Machines such as roll forming lines, coil processing equipment, CNC machines, robotic systems, and automated production lines often rely on Programmable Logic Controllers (PLCs) to control machine operations.
With remote access systems in place, engineers can view machine data, modify PLC programs, monitor alarms, and troubleshoot faults without traveling to the factory where the machine is installed. This capability can significantly reduce downtime and service costs.
However, implementing a reliable and secure remote PLC access system requires several hardware and software components. The total cost can vary depending on the complexity of the system, the number of machines, and the level of cybersecurity required.
Understanding the typical costs involved helps factories and machine manufacturers plan their remote monitoring infrastructure.
Typical Components Required for Remote PLC Access
A standard remote PLC access system includes several key components.
1. Industrial VPN Router or Gateway
This device connects the machine network to the internet and creates a secure VPN tunnel for remote access.
2. Internet Connection
Machines must have internet connectivity through factory broadband, fiber, or cellular networks.
3. Remote Access Software Platform
Many remote access systems use cloud platforms that manage connections between engineers and machines.
4. Network Security Infrastructure
Firewalls, network segmentation, and authentication systems protect the machine network.
5. Installation and Configuration
Engineering time is required to configure the PLC network, router, and VPN system.
Each component contributes to the overall cost of the system.
Hardware Costs for Remote PLC Access Systems
The most common hardware used in remote PLC access systems is an industrial VPN router or remote access gateway.
Industrial VPN Routers
Industrial routers designed for remote machine access typically cost between:
- £150 – £500 for basic industrial VPN routers
- £500 – £1000 for advanced industrial VPN gateways
For example, industrial VPN routers designed for remote machine access can cost around €553 (approximately £470) for models like the EWON Cosy+ remote access router.
More advanced industrial routers capable of remote monitoring and PLC data collection may cost around €786 (approximately £670) or more depending on features.
These routers establish encrypted VPN connections between machines and remote engineers.
Industrial IoT Gateways and Edge Devices
Some remote PLC systems include additional devices for data collection and monitoring.
Typical costs:
- £300 – £1000 for industrial IoT gateways
- £500 – £1500 for advanced edge computing devices
These devices collect machine data from PLC systems and transmit it to monitoring platforms.
Industrial Firewall and Network Security Costs
Factories often install industrial firewalls to protect machine networks from unauthorized access.
Typical firewall costs:
- £300 – £1500 for small industrial firewalls
- £2000 – £5000+ for enterprise industrial security appliances
Security infrastructure is essential for protecting PLC systems from cyber threats.
Software and Cloud Service Costs
Many remote PLC access systems use cloud-based remote access platforms.
Typical software costs include:
Remote Access Cloud Platform
Some systems provide basic access for free with hardware purchases, while advanced features may require subscriptions.
Typical cost range:
- Free to £300 per year for basic remote access portals
- £500 – £1500 per year for advanced enterprise remote access platforms
In industrial environments, remote access platforms may charge annual licensing fees for connection management and user access.
Cellular Data Connectivity Costs
Some machines use 4G or 5G routers when factory internet access is unavailable.
Typical cellular costs include:
- £10 – £40 per month for mobile data plans
- £150 – £500 for industrial cellular routers
Cellular connections are common for remote installations or field equipment.
Engineering and Installation Costs
Setting up a remote PLC access system also requires engineering time.
Typical installation costs may include:
- configuring industrial routers
- setting up VPN connections
- configuring firewall rules
- integrating PLC communication
Engineering setup costs typically range from:
- £300 – £1000 for simple installations
- £1500 – £5000+ for complex multi-machine installations
The complexity of the automation system affects setup costs.
Typical Total Cost per Machine
For most industrial machines, a basic remote PLC access system typically costs:
Basic Setup
- VPN Router: £300 – £700
- Installation: £300 – £800
- Cloud access: Free – £300/year
Total setup cost:
£600 – £1500 per machine
Advanced Setup
- Industrial gateway: £600 – £1200
- Firewall/security hardware: £500 – £2000
- Installation and configuration: £1000 – £3000
- Cloud services: £500 – £1500/year
Total setup cost:
£2500 – £6000+ per machine
Cost of Remote PLC Access for Multiple Machines
Factories often connect multiple machines to the same remote monitoring system.
In these cases:
- one central firewall protects the network
- multiple routers connect individual machines
- monitoring software manages all machines
This architecture reduces the cost per machine.
Typical cost per machine in multi-machine installations may drop to:
£400 – £1200 per machine
Cost Savings from Remote PLC Access
Although remote PLC access systems require an initial investment, they often generate significant savings.
Major benefits include:
Reduced Travel Costs
Engineers can diagnose machine faults without traveling to the factory.
Faster Troubleshooting
Remote diagnostics reduce machine downtime.
Global Machine Support
Machine manufacturers can support installations worldwide.
Predictive Maintenance
Remote monitoring allows engineers to identify problems early.
These benefits often recover the system cost quickly.
Remote PLC Access Costs for Roll Forming Machines
Roll forming machines used in steel manufacturing are often installed in factories worldwide. Machine manufacturers frequently provide remote technical support for these machines.
Installing remote PLC access systems allows engineers to diagnose machine problems quickly and assist operators without traveling to the site.
This significantly reduces service costs for machine manufacturers and customers.
Remote PLC Access Costs for Coil Processing Lines
Coil processing lines used in steel service centers include multiple automated machine sections such as decoilers, levelers, slitters, and stacking systems.
Remote monitoring and PLC access systems allow engineers to troubleshoot automation issues and monitor production performance across the entire production line.
Installing remote access systems helps maintain stable production operations.
How Machine Matcher Helps Implement Remote PLC Systems
Machine Matcher helps manufacturers implement remote monitoring and diagnostic systems for industrial machines installed worldwide.
These systems include:
- secure VPN remote access
- industrial routers and gateways
- machine monitoring platforms
- PLC diagnostic systems
By integrating secure networking infrastructure with automation expertise, Machine Matcher enables engineers to support machines remotely while maintaining strong cybersecurity protection.
Frequently Asked Questions
What is the cheapest way to set up remote PLC access?
Using a basic industrial VPN router with a secure VPN connection.
How much does a remote PLC router cost?
Industrial VPN routers typically cost between £150 and £1000 depending on features.
Do remote PLC systems require monthly fees?
Some platforms charge subscription fees, while others offer free basic access.
Can multiple machines use one remote access system?
Yes. Multiple machines can connect through a shared network infrastructure.
Is remote PLC access worth the cost?
Yes. Reduced downtime and service costs usually recover the investment quickly.
Conclusion
Setting up a remote PLC access system typically costs between £600 and £6000 per machine, depending on the complexity of the automation system and the level of security infrastructure required.
Basic systems may only require an industrial VPN router and simple configuration, while advanced installations may include industrial gateways, firewalls, and monitoring platforms.
Although these systems require an initial investment, remote PLC access significantly improves machine support capabilities, reduces downtime, and lowers service costs for industrial machines installed worldwide.