As Wi-Fi 7 begins to gain traction in enterprise networks, industrial operators are exploring how next-generation wireless technology could improve their operations.
However, according to IDS-INDATA, success in these environments won’t depend on Wi-Fi 7 technology alone. It will depend on how well wireless solutions are designed and adapted to the industrial setting.
“Good wireless design has always been the make-or-break factor in industrial deployments,” says Charlie McRae, Systems Engineer at IDS-INDATA. “You can have the latest standard, but if your signal can’t make it through a steel-clad factory floor or if devices aren’t properly segmented, performance and reliability will suffer.”
Cisco’s research highlights that today’s top Wi-Fi 6E and Wi-Fi 7 use cases include video collaboration, IP voice, and transitioning from wired to wireless connections.
Looking ahead, demand is expected to shift toward IoT devices and sensors, point-of-sale systems, and new applications, all of which will place heavier demands on wireless infrastructure.
These evolving needs underscore the importance of robust wireless design and capacity planning tailored to complex industrial environments.
Focus on Foundations, Not Features
Wi-Fi 7 introduces powerful capabilities like 6 GHz support, Multi-Link Operation, and WPA3 security. However, many industrial client devices still operate on Wi-Fi 4 or 5 and cannot take advantage of those features.
Without a strong infrastructure, simply deploying Wi-Fi 7 APs won’t resolve performance or reliability issues.
IDS-INDATA has identified three core risks that could undermine next-generation wireless performance:
1. Underpowered Infrastructure
Many industrial sites still rely on outdated Cat5 cabling and 1 Gb switches. These cannot support high-throughput traffic, creating bottlenecks even with modern APs in place.
Impact: Slowdowns in automation, quality control, and IIoT systems; reduced ROI from new technologies.
2. Inadequate Power Provisioning
While not all Wi-Fi 7 APs require PoE++ (802.3bt), many high-end or tri-band models do. Rugged environments with high heat, dust, or moisture often demand access points with higher power consumption, which legacy switchgear may not support.
Impact: Degraded AP performance, reduced coverage, or outright failure—leading to rollout delays and unexpected costs.
3. Poor RF Planning in Harsh Environments
Factory environments present significant RF challenges due to the presence of metal structures and numerous interference sources.
Wi-Fi 7’s use of the 6 GHz band and wider channels offers new performance opportunities, but it also demands precise RF planning.
According to Cisco, IoT devices and sensors will be major drivers of 6 GHz adoption; yet, these high-throughput, low-latency applications depend heavily on careful spectrum management and environmental assessment. In such demanding environments, even a minor misstep in RF design can significantly impact performance.
Impact: Instability, roaming issues, and unpredictable performance can disrupt production operations, leading to significant disruptions.
Security Requires More Than WPA3
WPA3 is mandatory in Wi-Fi 7, but it’s not enough to protect industrial networks on its own. Most deployments will still rely on legacy protocols for backwards compatibility, and advanced features like Multi-Link Operation may introduce new attack surfaces.
Effective security demands a layered approach, including segmentation, monitoring, and strict device access control.
“Too many teams assume upgrading access points equals upgrading security or speed,” McRae adds. “In reality, infrastructure readiness and wireless design are what make or break a deployment.”
A Smarter Path to Wireless Modernisation
Whether organisations are staying on Wi-Fi 5 or planning a move to Wi-Fi 7, IDS-INDATA recommends a clear, foundational strategy:
- Upgrade to shielded Cat6A cabling and multigigabit-ready switches
- Conduct power audits and ensure PoE++ support where needed
- Use environmental assessments and ruggedised access points for harsh areas
- Perform advanced RF surveys to optimise capacity, roaming, and interference mitigation
- Design segmented wireless networks that separate IT and OT traffic
- Consider managed network services to maintain long-term reliability and visibility
“It’s not just about installing access points,” says McRae. “It’s about building a wireless ecosystem that’s future-proof, secure, and designed for the realities of industrial operations.”
With new device and application creation ranked as a top future Wi-Fi 7 use case by Cisco, enterprises must prioritise segmentation, continuous monitoring, and flexible infrastructure to handle growing traffic loads and increasingly diverse device types.
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