Skip to content
Zappsec
Case Study · Manufacturing

Global Network Security Modernization for a Plastics Manufacturing Enterprise

Automated discovery and unified firewall migration standardized IT/OT segmentation across hundreds of factories.

CybersecurityNetworkingOT and EdgeZero Trust
Global Network Security Modernization for a Plastics Manufacturing Enterprise - architecture illustration
Enterprise overview

Global plastics manufacturing enterprise

200+
Factories
500+
Firewalls

A global plastics manufacturer runs hundreds of factories - each with its own network history, its own firewall vendors and its own approach to IT/OT separation.

The Problem

A global factory estate with 200+ inconsistent security postures.

Inconsistent segmentation

IT/OT boundaries varied factory by factory.

Mixed vendor estate

Firewall vendors and versions diverged across regions.

Manual change

Every policy update was a bespoke project.

The Zappsec Solution

Automated discovery, unified migration, standardized segmentation.

  1. 1
    Automated discovery

    Programmatic inventory of policies and topology across the estate.

  2. 2
    Firewall migration factory

    Unified migration pipeline across vendors and versions.

  3. 3
    Standardized IT/OT segmentation

    One segmentation pattern applied consistently across sites.

Architecture

Reference architecture at a glance

Global factories converge on one segmentation and firewall pattern - discovered, migrated and enforced through automation.
Global factories converge on one segmentation and firewall pattern - discovered, migrated and enforced through automation.
Outcomes

Outcomes that changed the operating model

100%
IT and OT segmentation compliance

One pattern enforced across every factory.

200+
Factories aligned

Global estate on a single security baseline.

Factory security shifted from bespoke effort to a repeatable, enforceable pattern.

Technologies and platforms

The stack behind the transformation

FortinetPalo Alto NetworksTerraform

Related Zappsec capabilities

Cybersecurity

Zero Trust, SSE, workload and OT security delivered as policy-as-code.

Explore capability
Networking

Campus, SD-WAN, data center and hybrid cloud networking as one architecture.

Explore capability

More transformation stories

What could this architecture unlock for your enterprise?

Talk with a Zappsec architect about the cloud, network, security, identity or data platform behind your next transformation program.

Talk to an Architect Explore all insights