Manufacturers and production companies
A line stoppage means immediate, significant loss. The test shows how an attacker could get from the office network to the production line.
/ OT PENETRATION TESTING
OT Penetration Testing
Protecting industrial systems follows different rules from protecting an office network: safety, availability and process continuity come first. Our OT penetration testing shows what an attacker could reach, using methods that do not put production at risk.
[ 01 ] / WHAT IT IS
What is OT penetration testing, and how is it different from IT testing?
In short
OT penetration testing is a security assessment of industrial control systems (ICS, SCADA, PLCs, HMIs) and the networks that support them. It shows exploitable weaknesses while protecting the safety and continuity of the production process, with particular attention to the IT/OT boundary, remote access and network segmentation.
OT (operational technology) is the world of systems that control physical processes: PLCs, SCADA systems, HMIs, sensors and drives. When these are attacked, the consequence is not just lost data: production can stop, equipment can be damaged and people can be put at risk. Many OT devices are also old, cannot be patched, and speak vendor protocols (Modbus, S7, DNP3, OPC UA, PROFINET, EtherNet/IP) that were never designed to be secure.
That is why the methodology for OT penetration testing is far more cautious than in IT. Passive observation, lab or test environments, controlled windows and close work with process engineers are all part of the approach. We run active tests only where they are proven safe. We follow the logic of penetration testing, but safety outranks coverage in every decision.
The most common real-world risks sit at the IT/OT boundary and in remote access: from a compromised office network, or via a vendor VPN, an attacker can reach the industrial network. Checking segmentation, access control and detection is therefore the heart of the test. NIS2 covers manufacturers and the energy sector, and IEC 62443 is the accepted standard for industrial security.
Standards and frameworks
- IEC 62443
- NIST SP 800-82
- Purdue model
- MITRE ATT&CK for ICS
- NIS2
- ISO/IEC 27019
[ 02 ] / WHO IT'S FOR
Who benefits from OT penetration testing?
Any organization whose operations depend on industrial control systems, and where availability or physical safety is critical.
Energy and utility providers
Continuity of supply matters enormously, and the sector falls under NIS2. Regular testing is part of risk management.
Building-automation and logistics operators
BMS, warehouse automation and conveyor systems also use industrial protocols and are often exposed to the internet.
Machine builders and system integrators
Customers increasingly ask for security evidence about machines and installed solutions, for example to IEC 62443.
Water utilities and waste operators
As part of critical infrastructure, the sector needs strong protection, while its systems are often old and lightly defended.
IT leaders and OT engineers
The test gives IT and OT a common language: a concrete path that both teams can work on.
[ 03 ] / WHAT'S INCLUDED
What OT penetration testing covers
Each element is tailored to the safety requirements of the specific plant, agreed with process engineers.
01
Architecture and data-flow review
We map the plant network, its Purdue model levels, the IT/OT boundary and communication paths.
02
Passive network monitoring
We discover industrial traffic and devices without disturbing the process, which exposes unknown assets and risky connections.
03
IT/OT boundary and segmentation
We test firewall rules, DMZs, jump hosts and traffic between zones, and demonstrate the attack path from the office network into the industrial network.
04
Remote access and vendor connections
VPNs, maintenance and supplier access, remote desktop tools and the strength of authentication.
05
Engineering workstations, SCADA and HMI
Operating systems, software, privileges and configuration on the machines that support control.
06
PLCs and industrial protocols
We review device configuration, authentication and protocols. Active testing is done only in a lab or in a demonstrably safe way.
07
Wireless and physical security
Industrial wireless networks, and physical access to control cabinets and network ports.
08
Detection and response
We check whether OT monitoring and your SOC notice suspicious activity in the industrial environment.
[ 04 ] / HOW IT WORKS
How OT penetration testing runs
Safety shapes every step. Before testing anything, we agree what could be affected and how we prevent it.
Risk analysis and agreement
With operators and process engineers we decide what can be tested, when and how, and fix stop conditions and the emergency procedure.
Discovery and passive analysis
From documents and passive traffic analysis we learn the plant, its devices and network connections, without disturbing the process.
Preparing the test environment
Where possible, we try techniques first in a lab or a replicated (digital twin) environment so that risk in live operation is minimal.
Controlled testing
Tests run in the agreed window, in constant contact with operators, with checkpoints between stages.
Reporting and impact assessment
Findings are rated by physical and business impact, with recommendations that make sense to both IT and OT.
Remediation support and retest
We help implement the plan (segmentation, hardening, access control), then verify the result.
[ 05 ] / WHAT IT SOLVES
What OT penetration testing solves, and why it pays off
The true exposure of OT systems is often unknown: decades of build-up, undocumented connections, old devices and forgotten remote access. The test makes real attack paths visible and points your effort at the most effective defenses in an environment that is expensive and hard to change.
It also provides evidence for regulators and customers: NIS2, IEC 62443 and customer security requirements increasingly expect documented, risk-based testing.
- reveals the real risk at the IT/OT boundary and in remote access
- uncovers unknown assets and risky connections
- grounds segmentation and compensating-control decisions
- evidence for NIS2, IEC 62443 and your customers
- protects production continuity
What you receive
- executive summary of business and physical risk
- network and asset inventory from discovery
- proven attack paths
- risk ratings by impact
- segmentation and hardening recommendations
- retest report
[ 06 ] / WHY QYNTAR
Why have Qyntar run your OT penetration testing?
Because OT testing needs offensive skill as much as process knowledge and caution.
Safety first
We favor passive methods, labs and agreed windows so that testing never endangers production or people.
IT and OT together
Security specialists and engineers work side by side, so recommendations are workable in an industrial setting.
A practical risk picture
We rate findings by physical and business impact, not only by technical severity.
Standards-based method
We build on IEC 62443 and NIST SP 800-82, which also supports your compliance work. See compliance support.
[ 07 ] / FAQ
Frequently asked questions: OT Penetration Testing
What is OT penetration testing?
A security assessment of industrial control systems (ICS, SCADA, PLCs, HMIs) and industrial networks that shows exploitable weaknesses while protecting production continuity and physical safety.
Could the test endanger production?
The methodology exists to prevent exactly that: passive observation, lab or test environments, agreed windows and stop conditions. We run active tests only in a demonstrably safe way, agreed with operators. No testing is risk-free, which is why the upfront risk analysis is fundamental.
How is an OT test different from an IT penetration test?
In OT, availability, physical safety and process continuity come first, the systems are old and fragile, and the protocols are not secure by design. That calls for more cautious, passive methods and much closer cooperation with operators. Combined with an IT penetration test it gives the complete picture.
What is IEC 62443?
The international series of standards for the cybersecurity of industrial automation and control systems. It sets organizational, system-level and component-level requirements for operators, integrators and manufacturers.
Does NIS2 apply to our manufacturing or energy company?
NIS2 covers the energy sector and several manufacturing sectors. Whether you are in scope depends on your size and activity. See NIS2 compliance. This is not legal advice.
Can old, unpatchable devices be tested?
Yes, with care: old devices are often only assessed passively or in a lab, and the risk is handled with segmentation, hardening and monitoring. The test shows exactly where compensating controls are needed.
How long does an OT penetration test take?
From a few days to several weeks, depending on the plant and scope. Preparation and coordination often take longer than the testing itself. We give a firm schedule after scoping.
[ 08 ] / RELATED SERVICES
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