Virtual5, when the PLC move to the cloud at Simei

From Traditional Control to Virtualised Control

Digital transformation is reshaping the future of industrial automation. The convergence of Information Technology (IT) and Operational Technology (OT) is creating new opportunities to make production plants more flexible, connected and ready to meet tomorrow’s challenges. Within this context, Omnia Technologies developed VIRTUAL5, a project designed to validate a new process control model based on virtualised PLCs, edge and cloud infrastructures, and a private industrial 5G network, in collaboration with Schneider Electric and TIM.

Why Rethink the Traditional PLC?

For more than thirty years, the PLC has been at the core of industrial automation. Today, however, growing demands for flexibility, scalability and connectivity require new approaches capable of seamlessly integrating edge and cloud infrastructures with advanced data analytics tools. Through VIRTUAL5, Omnia Technologies has explored a new process control model based on virtualised PLCs, moving automation logic from dedicated hardware to a software-based platform while maintaining the high standards of reliability, operational continuity and security required in industrial environments.

The Use Case: A Connected, Data-Driven Winery

To validate the model, Omnia Technologies selected a real production facility within the wine industry, characterised by a high level of digitalisation and process monitoring. The objective was to demonstrate how an infrastructure combining virtualised PLCs, private 5G connectivity, edge and cloud technologies, and advanced supervisory platforms can support a more flexible, scalable and integrated approach to industrial process control.

The Role of 5G in Industrial Automation

One of the key components of VIRTUAL5 is the use of a private industrial 5G network. Thanks to its low latency, reliability and advanced security features, 5G enables more flexible and connected automation architectures, linking production assets, supervisory systems and digital platforms. While representing a strategic element of the project, 5G is not a technological constraint. The architecture developed by Omnia Technologies is designed to adapt to different connectivity infrastructures, dynamically distributing control functions between the field, edge and cloud according to the performance of the available network.

From Plant Floor to Cloud: A Connected Ecosystem

VIRTUAL5 brings together production systems, connectivity, control and supervision within a single digital ecosystem. Through virtualised PLCs, edge and cloud technologies, and advanced connectivity, the project demonstrates how more flexible, scalable and future-ready automation architectures can be achieved.

At the heart of VIRTUAL5 lies the concept of Software Defined Automation. Control software is no longer tied to a specific hardware device but can instead be deployed flexibly across the field, edge and cloud layers. Much like in the IT world, applications and infrastructure become independent of one another, simplifying plant evolution, maintenance and scalability. This approach encourages deeper integration between Information Technology and Operational Technology while paving the way for more open and adaptable systems.

Beyond Control: Creating Value Throughout the Lifecycle

Virtualisation unlocks new digital service opportunities, including remote monitoring, predictive maintenance, advanced support and centralised updates. This approach enables manufacturers to support customers throughout the entire lifecycle of their assets, transforming technology into a tangible opportunity for continuous improvement and long-term operational performance.

Looking Ahead

VIRTUAL5 represents a concrete step towards the next generation of industrial automation. The convergence of virtual PLCs, advanced connectivity, edge computing, cloud technologies and artificial intelligence is opening new possibilities for designing production systems that are more efficient, sustainable and easier to evolve over time.

For Omnia Technologies, innovation is not just about developing new technologies. It is about creating solutions that deliver lasting value for customers, both today and in the years ahead.