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OT / Cyber Security

Air-Gapped Governance for Operational Technology

Industrial control systems, SCADA networks, and manufacturing processes were built for reliability, not cybersecurity. As IT/OT convergence accelerates, these systems face threats they were never designed to withstand.

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Control

OT / Cyber Security

If your IT network can reach your OT network, so can an attacker. The only real air gap is a physical one, not a firewall rule, not a VLAN, not a DMZ. Firevault Control enforces physical IT/OT separation at the hardware level.

Zero

IT-to-OT crossover pathways

24/7

Operational continuity maintained

9

Governance modules for OT isolation

Full

IEC 62443 compliance evidence

The Challenge

OT environments are increasingly exposed.

IT/OT Convergence

Shared connectivity between IT and OT networks exposes industrial systems to IT-borne threats.

Legacy Systems

Legacy OT systems lack authentication and encryption, and patching requires downtime.

Configuration Tampering

Attackers alter PLC programs and SCADA configurations with changes that go undetected for weeks.

The Scenario

Scenario: Ransomware Crosses IT into OT

A manufacturing plant's IT network is compromised through a phishing email targeting the finance team. The ransomware spreads laterally across the corporate network within 4 hours. Because the historian server bridges IT and OT, sharing a network path for reporting, the ransomware reaches the OT network by hour 6. PLC configurations are encrypted, SCADA displays go dark, and the plant loses supervisory control of three production lines. Recovery takes 18 days because backup PLC configurations were stored on a network-attached share, also encrypted. With Firevault Control, the Isolate module physically disconnects OT backup data from IT networks. The Transfer module governs any data movement between zones through policy-controlled windows. The ransomware reaches IT but cannot cross a connection that physically does not exist.

"We had a firewall between IT and OT. We thought that was an air gap. When the ransomware jumped across, we realised a firewall rule is just software, and software can be bypassed. We needed physical disconnection."

Solution Blueprint

Hardware-enforced IT/OT separation.

OT environments gain hardware-enforced separation from IT networks without requiring changes to existing industrial infrastructure. SCADA configurations, PLC programs, and process data are protected in offline vaults, ensuring rapid recovery from any compromise and maintaining 24/7 operational continuity.

  • Physical IT/OT segmentation enforcing true air-gap separation
  • Configuration protection for SCADA, PLC programs, and recipes in offline vaults
  • Controlled access windows for time-bound maintenance and updates
  • Out-of-band management with dedicated cellular connectivity
  • Historian data protection against ransomware
  • Immutable audit trail for safety compliance and regulatory evidence
Isolate

Isolate, Physical IT/OT Separation

Module 1 of 4

Enforces hardware-level disconnection between IT and OT network zones. No shared network path exists between corporate systems and industrial control infrastructure. SCADA configurations, PLC programs, and historian data are physically unreachable from IT-borne threats, regardless of what malware, credentials, or zero-days an attacker possesses.

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Key Capabilities

PLC & SCADA Config Protection

Golden copies of PLC programs, SCADA configurations, and HMI settings stored in hardware-encrypted offline vaults, immune to network-based attacks.

Historian Backup

Process historian data protected in physically disconnected storage, ensuring operational records survive ransomware and are available for safety investigations.

Controlled Maintenance Windows

Time-bound access windows for firmware updates and configuration changes, physical paths open only during authorised periods with full audit trails.

IEC 62443 Evidence

Automated compliance logging maps to IEC 62443 zone and conduit requirements, demonstrable physical separation, not just logical segmentation.

Zero-Downtime Deployment

Deploys alongside existing OT infrastructure without requiring changes to PLCs, SCADA systems, or network architecture, no production disruption.

Demo to Live

Adoption Guide

Step 1

OT Environment Audit

Map all IT/OT boundaries, shared network paths, historian connections, and remote access points to identify where physical separation is required.

Step 2

Zone and Conduit Design

Align Control modules to IEC 62443 security zones and conduits, designing physical separation that maps directly to your compliance requirements.

Step 3

Non-Disruptive Pilot

Deploy alongside existing PLCs, SCADA systems, and RTUs without any changes to operational equipment, zero production downtime during validation.

Step 4

Production Go-Live

Activate controlled maintenance windows, historian backup replication, and immutable audit trails across your entire OT environment.

Step 1

OT Environment Audit

Map all IT/OT boundaries, shared network paths, historian connections, and remote access points to identify where physical separation is required.

Step 2

Zone and Conduit Design

Align Control modules to IEC 62443 security zones and conduits, designing physical separation that maps directly to your compliance requirements.

Step 3

Non-Disruptive Pilot

Deploy alongside existing PLCs, SCADA systems, and RTUs without any changes to operational equipment, zero production downtime during validation.

Step 4

Production Go-Live

Activate controlled maintenance windows, historian backup replication, and immutable audit trails across your entire OT environment.

Commercial Advantage

Win Business, Earn Trust, and Build Reputation with Butterfly

Butterfly is an operational model that helps organisations structure sensitive data to close deals faster, strengthen client relationships, and demonstrate the governance maturity that wins enterprise contracts.

Built on the VPPP framework (Vault, Policy, Permissions, Purpose), Butterfly maps your sensitive data and assigns dedicated Vaults by role, relationship, and purpose, turning data stewardship into a competitive advantage.

Deal Readiness

Governed materials ready to share with confidence

Client Trust

Demonstrate stewardship that earns loyalty

Board Confidence

Clear governance that inspires stakeholders

Enterprise Scale

Structure data governance across your organisation

Butterfly deployment model

Who Uses Butterfly?

  • Sales Teams

    Secure client proposals, pricing, and commercial intelligence

  • Service Providers

    Exchange sensitive documents with clients through governed Vaults

  • Businesses

    Protect strategic plans, IP, and competitive intelligence

  • Family Offices

    Structure data governance across principals, staff, and advisors

Questions

Frequently Asked

Ready to take the next step?

See how Control can govern your data paths with physical enforcement no software exploit can bypass.

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