How to Choose an OPC Server

In India, multi-vendor environments with European, Japanese, and U.S. equipment are common. Introducing an OPC server that does not fit your site can increase the risk of data loss or line stoppages. To help you avoid these risks, this article outlines how to choose an OPC server.

Key Points to Check When Choosing an OPC Server
for Manufacturing Sites in India

Connectivity and Scalability

The first point to check is whether the OPC server can provide stable connectivity with your existing PLCs and equipment. Check whether it supports equipment from major manufacturers such as Siemens, Rockwell, Mitsubishi, and Schneider, as well as communication standards such as EtherNet/IP, Modbus, PROFINET, and OPC UA.

You should also check scalability, including whether CNC machines, power meters, and other devices can be added flexibly in the future.

Reliability, Security, and Operational Continuity

Stable operation of the OPC server is also an important point. Check whether it can maintain performance as the number of tags and communication volume increase, and whether it supports redundancy and recovery in the event of a failure.

Security features such as authentication and encryption, as well as support for OPC UA, are also important. Comparing whether each configuration supports safe, continuous operation while reducing the risk of site stoppages can help prevent problems after deployment.

Support, Licensing, and Ease of Future Migration

With post-deployment operations in mind, check the support structure and licensing model, including whether it is based on the number of devices or tags. It is important to understand the availability of technical support and how costs may increase, then choose a solution that also takes migration from legacy environments and future OPC UA support into account.

OPC-Related Products Commonly Compared in India

This section explains the differences among OPC-related products that are often compared.

Differences Between Kepware Server and Matrikon OPC Products

Kepware Server is a single large connectivity platform, while Matrikon OPC Products is a product family with products organized by use case and conversion type. The right choice depends on whether you prioritize connectivity or analysis. The following article compares the two solutions in terms of license structure, cost, and support for multi-vendor environments.

Role Differences Between Kepware Server and ThingWorx

The difference between the two lies in their roles. Kepware Server is a connectivity platform for linking PLCs, equipment, and upper-level systems. ThingWorx is an IIoT platform for using data through visualization, analysis, and other applications. The product you choose depends on which role you prioritize. The following article summarizes the differences and key selection points in detail.

By Use Case: Quick Selection Guide

Check the selection criteria that matter most based on the case closest to your site’s challenges.

Large-Scale Multi-Vendor Integration

For large sites with equipment from multiple manufacturers, a product that can standardize connectivity design is recommended. Focus on the range of supported equipment and communication standards, ease of setup and operation when adding equipment, and whether connectivity methods can be standardized. The TOP page below introduces Kepware Server, which helps centralize management across multiple sites.

Legacy Migration and High-Reliability Integration

If you want to make use of an OPC Classic environment or legacy equipment, focus on maintaining connectivity with existing equipment while also considering ease of future migration to OPC UA. At the same time, check whether the product can support stable operation while reducing the risk of stoppages, and whether it is easy to monitor and maintain. The article below introduces Matrikon OPC Products for sites that prioritize migration from legacy environments.

Legacy Environments with a Mix of Japanese-Made PLCs

If your site runs on a legacy environment with PLCs from multiple manufacturers, including Japanese brands accumulated over years of equipment additions and replacements, compatibility across PLC generations and brands becomes a key concern.
For sites that need to add or change equipment without stopping production lines, DeviceXPlorer from Takebishi Corporation is introduced below. It supports connectivity with many devices, including older and mixed-generation PLCs from Japanese and other manufacturers, and includes hot configuration functionality.