Why OT Systems Demand a New Approach to Authentication?

Cyber threats targeting Operational Technology (OT) systems have surged in recent years, placing critical infrastructure—such as energy, water, and transportation networks—at unprecedented risk. While industrial operations increasingly integrate OT with Information Technology (IT), this convergence has widened the attack surface, making cybersecurity a pressing concern.

The world enters 2025 at the precipice of a cyber age where the backbone of modern industry—Operational Technology (OT)—faces unprecedented risks. While the integration of OT with IT has streamlined operations and improved efficiency, it has also widened the attack surface for cybercriminals. These growing vulnerabilities demand urgent attention, particularly as critical sectors such as energy, transportation, and water utilities remain frequent targets.

The Scale of OT Cyber Threats

Recent research highlights the scale of the problem. A 2024 report by ABI Research and Palo Alto Networks found that nearly 70% of industrial organisations experienced cyberattacks in 2023, with 26% facing attacks on a weekly basis. One in four companies suffered operational disruptions due to these breaches.

Additionally, 74% of industry leaders expect AI-driven cyberattacks to become a major threat to OT security, while 70% view the rapid adoption of 5G technology as an emerging risk vector.

The Weak Link in OT Security

A closer look at OT security failures reveals a common weak link: authentication. Programmable Logic Controllers (PLCs), the backbone of industrial automation, remain highly vulnerable due to outdated authentication mechanisms. Many PLCs still rely on fixed passwords—often left at their factory defaults or shared among operators—making unauthorised access alarmingly easy. In fact, research shows that 81% of OT security breaches stem from weak passwords or credential theft.

A study analysing 23 widely used PLC models from 13 major vendors uncovered critical vulnerabilities, including inadequate access controls and weak proprietary security protocols. Attackers were able to exploit these flaws to hijack PLC functions remotely, bypassing standard defenses without even requiring advanced hacking techniques.

The Risks of a Reactive Security Approach

Addressing these challenges requires more than just periodic security patches from PLC manufacturers. The traditional approach—waiting for updates to fix vulnerabilities—leaves industrial operators exposed for extended periods. This delay in response has already contributed to severe cyber incidents.

For example, in early 2024, Mexico recorded over 31 billion cybercrime attempts within six months, primarily targeting industrial infrastructure due to the country’s expanding economic ties and industrial base. 

A Proactive Solution: Dynamic Authentication

A fundamental shift in OT security strategy is needed—one that prioritises real-time authentication rather than reactive patching. Technologies such as dynamic authentication, which eliminates static passwords and prevents unauthorised access attempts, offer a way forward.

Solutions like the OTAC Trusted Access Gateway provide a centrally managed, passwordless authentication method for PLCs, ensuring that access is granted only to verified users without disrupting existing automation processes.

Strengthening OT Security for the Future

With cyber threats growing in sophistication and frequency, relying on outdated authentication mechanisms is no longer viable. Industrial organisations must embrace proactive security measures to protect their critical systems, minimise operational disruptions, and ensure resilience against evolving cyber risks.