Optimising IIoT Control Systems at Demcon: Integrating MQTT,
Sparkplug B, and ISA-88 for Unified Automation
Ana Pintilie
1
, Remco Poelarends
2
and Andrea Capiluppi
1 a
1
Department of Computing Science, University of Groningen, The Netherlands
2
Technology and Innovation Department, Demcon, The Netherlands
Keywords:
Industrial Internet of Things (IIoT), MQTT, Sparkplug B, Unified Namespace, Industry 4.0, .NET
Architecture, TwinCAT, Industrial Automation.
Abstract:
This paper addresses the challenges in optimizing PLC-based industrial control systems at Demcon to meet
IIoT standards. Through a collaboration with the University of Groningen (NL), we redesigned the archi-
tecture using MQTT and Sparkplug B to enable scalable, real-time communication and introduced a Unified
Namespace (UNS) for seamless data exchange. The results demonstrate improved flexibility, scalability, and
latency reduction, validating the approach in an industrial environment and highlighting its broader potential
for IIoT adoption.
1 INTRODUCTION
Industry 4.0 has revolutionized manufacturing by in-
tegrating IIoT and advanced analytics, enabling real-
time data exchange and decision-making. However,
Demcon’s PLC-based control systems face challenges
in scalability, communication, and real-time monitor-
ing, limiting their ability to meet evolving industrial
demands.
This paper presents a case study on redesigning
Demcon’s architecture, leveraging MQTT and Spark-
plug B for scalable communication and introducing a
Unified Namespace (UNS) to standardize data flow.
The redesign aimed to address bottlenecks in real-
time control and enhance operational efficiency, pro-
viding a model for broader IIoT applications.
The remainder of the paper is structured as fol-
lows: Section 2 reviews relevant literature, Sec-
tion 3.2 and 4 outline the case study and the method-
ology, and Section 5 presents the findings. The pa-
per concludes with a discussion of implications (Sec-
tion 6) and future directions (Section 7).
2 RELATED WORKS
Industry 4.0 and IIoT have rapidly transformed var-
ious sectors, improving efficiency, flexibility, and
a
https://orcid.org/0000-0001-9469-6050
communication (Mohammed Saleem et al., 2024).
AI, machine learning and IoT technologies drive this
digital revolution, but challenges such as data man-
agement, security and workforce skills remain sig-
nificant (Z. Jan et al., 2022). Applications extend
beyond manufacturing, impacting healthcare, agri-
culture and education (Bharti Rana and S. Rathore,
2022), and automotive and transportation industries
also benefit from increased customisation and produc-
tivity (Dheeraj Nimawat and B. Gidwani, 2021).
From past research on IIoT, MQTT has often been
favored due to its lightweight nature, making it ideal
for resource-constrained environments (G. Reddy,
2017). Comparative studies have shown its efficiency
in terms of network overhead and latency compared
to CoAP and OPC UA (Iglesias-Urkia et al., 2017).
It has also been demonstrated that integrating MQTT
with Sparkplug B supports efficient data streaming,
with reduced traffic overhead and lower latency (Ko-
prov et al., 2022). However, the choice between
MQTT and other alternatives, such as OPC UA, de-
pends on specific application scenarios, with each of-
fering distinct advantages in industrial communica-
tion (Wang et al., 2022).
IoT communication protocols such as CoAP,
MQTT and OPC UA have been evaluated based on
metrics like latency, scalability and energy efficiency.
CoAP often outperforms other protocols in through-
put, while MQTT excels in resource-constrained en-
vironments (Silva et al., 2021). However, the se-
Pintilie, A., Poelarends, R. and Capiluppi, A.
Optimising IIoT Control Systems at Demcon: Integrating MQTT, Sparkplug B, and ISA-88 for Unified Automation.
DOI: 10.5220/0013142000003928
Paper published under CC license (CC BY-NC-ND 4.0)
In Proceedings of the 20th International Conference on Evaluation of Novel Approaches to Software Engineering (ENASE 2025), pages 351-358
ISBN: 978-989-758-742-9; ISSN: 2184-4895
Proceedings Copyright © 2025 by SCITEPRESS – Science and Technology Publications, Lda.
351

lection of protocol remains application-dependent, as
OPC UA can perform better in certain industrial sce-
narios (Rocha et al., 2019).
Integrating Operational Technology (OT) with In-
formation Technology (IT) systems in industrial envi-
ronments poses significant challenges due to interop-
erability and security concerns (Watson et al., 2017).
Protocols like MQTT Sparkplug B and OPC UA have
enabled seamless communication and vertical inte-
gration, enhancing flexibility in distributed control
systems (Koprov et al., 2022). Security challenges in
low-power IIoT devices have been mitigated through
the use of integration gateways and improved mod-
els (Mantravadi et al., 2020).
The ISA-88 standard enhances batch process flex-
ibility and standardisation across industries, including
pharmaceuticals and manufacturing (Jim Parshall and
Larry C. Lamb, 1999; De Minicis et al., 2014). In-
tegrating ISA-88 with Industry 4.0 concepts and IIoT
protocols (e.g., MQTT) has improved data flow and
real-time process management (Garcia et al., 2022),
reducing programming efforts and improving process
flexibility (Neugschwandtner et al., 2013).
The Unified Namespace (UNS) standardises data
flow, improving real-time communication and enter-
prise scalability (Abouzied et al., 2024; Li et al.,
2021). MQTT Sparkplug B aids in achieving UNS
by connecting Operational Technology networks to
cloud platforms (Koprov et al., 2022). Emerging
architectures, including Time-Sensitive Networking
(TSN) and hybrid wired-wireless systems, offer fur-
ther advancements in real-time performance and flex-
ibility (Simon Brooks and Ecehan Uludag, 2018).
Edge computing enhances real-time data process-
ing and bandwidth optimisation in IIoT systems (Qiu
et al., 2020). AI and machine learning further
improve predictive maintenance and process opti-
mization by enabling real-time analysis of sensor
data (Walas and Redchuk, 2021). Integrating AI mod-
els with IIoT improves fault detection and decision-
making, thus enhancing industrial efficiency (Gandhi,
2023; Kliestik et al., 2023).
3 KEY DEFINITIONS AND SITE
DESCRIPTION
Section (3) defines the key terms and technologies rel-
evant to the work performed at Demcon. Section 3.2
describes the industrial collaborator’s site and the is-
sues faced in the production site, while section 3.3
highlights the various aspects of intervention in the
architectural redesign.
3.1 Definitions and Technologies Used
• Industrial Internet of Things (IIoT): Connects ma-
chines and sensors in industrial environments for
enhanced efficiency, automation, and real-time
data analysis.
• MQTT: A lightweight messaging protocol ideal
for IIoT, enabling real-time communication be-
tween constrained devices (Stanford-Clark and
Truong, 2013).
• Sparkplug B: An MQTT extension providing
structured data exchange and lifecycle manage-
ment for IIoT devices (Solutions, 2016).
• Unified Namespace (UNS): A centralized reposi-
tory for real-time data and metadata
• PLC: Programmable Logic Controllers used in
automation to control machinery, though less scal-
able in modern IIoT environments.
• TwinCAT: A real-time PLC programming plat-
form used in industries like manufacturing and
pharmaceuticals.
• ISA-88 Standard: Provides guidelines for batch
control, standardizing processes for flexibility and
scalability. It defines three models: Process
Model (production steps), Physical Model (man-
ufacturing environment layers), and Procedural
Model (logical sequence of actions for batch con-
trol).
3.2 Description of the Site
The site selected for this research and implementation
is Demcon Industrial Systems
1
, based in Groningen.
The company was chosen for this project due to its ef-
forts to modernize the control system architecture and
adopt emerging Industrial Internet of Things (IIoT)
technologies, making it an ideal partner for testing in-
novative IIoT solutions.
Demcon operates a sophisticated manufacturing
environment that relies on PLCs to control industrial
processes and its operations are divided into multi-
ple production units, each equipped with specialised
machinery and sensors. These units are connected
through BRIX (see Figure 1), an internal architecture
based on the traditional industrial pyramid architec-
ture ((Martinez et al., 2021)). While effective for
legacy processes, this architecture poses challenges
in data flow, flexibility and scalability, particularly as
Demcon plans to transition to a smart factory model.
1
https://demcon.com/
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352

Figure 1: BRIX Architecture currently utilised in Demcon:
the dashed line encloses the extent of the intervention de-
scribed in this work.
The PLC also contains multiple automated mod-
ules that are abstracted according to the ISA-88 stan-
dard, as shown in Figure 2: redesigning them into a
hybrid architecture was one of the aims of the work
conducted within Demcon.
3.3 Formulation of the Problem
Demcon’s control systems rely on rigid and ineffi-
cient PLCs programmed with TwinCAT, causing bot-
tlenecks in data handling, real-time communication,
and device integration. The hierarchical structure lim-
its real-time data sharing across manufacturing levels,
delaying decision-making and reducing efficiency. As
operational demands grow, a unified communication
protocol is needed to manage the increasing number
of devices and sensors.
A key challenge is the lack of seamless integration
between operational technology (OT) and informa-
tion technology (IT) networks. Data collected at the
PLC level is not efficiently communicated to SCADA,
MES, and ERP systems, leading to delays in analytics
and feedback, which impacts efficiency. Additionally,
Demcon’s reliance on TwinCAT limits system scala-
bility and maintainability due to its rigid structure, not
suited for the dynamic needs of IIoT systems.
Recognizing these limitations, Demcon aims to
design a more flexible, agile system architecture using
IIoT technologies like MQTT and Sparkplug B to en-
hance operational efficiency and scalability. Figure 1
illustrates Demcon’s BRIX architecture, showing the
interaction between control modules and OT.
The proposed intervention, shown in Figure 1 by
a dashed grey rectangle, targets the controllers within
the BRIX architecture. Currently, the ISA-88 based
control modules (see Figure 2) are fully integrated
into the real-time controller. This research proposes
migrating most of these modules to a non-real-time
controller, retaining only essential base modules in
the real-time controller. Communication will occur
through a unified namespace managed by a broker.
The redesign of Demcon’s controlling system archi-
tecture leverages IIoT technologies by focusing on the
control logic within the PLC (the BRIX controllers in
Figure 1), a key element of the traditional automation
pyramid. The current system, limited by the PLC’s
memory and processing, operates in a rigid environ-
ment. A planned migration from a PLC-centred to
a hybrid architecture moves the majority of system
logic to a .NET environment, addressing these con-
straints and enabling more complex control logic and
real-time data processing.
The intervention also implements the MQTT pro-
tocol with Sparkplug B as the backbone for commu-
nication between the migrated .NET modules and the
PLC. MQTT’s publish/subscribe model supports effi-
cient data exchange across production, while Spark-
plug B ensures unified data management and state
control. This enhances scalability, enabling easier de-
vice integration and real-time production monitoring.
Finally, a unified namespace (UNS) standardises
data flows between operational levels, serving as a
”single source of truth” for system data. The UNS
eliminates data exchange bottlenecks, consolidating
communication into a coherent structure. This re-
design improves flexibility and efficiency, allowing
Demcon to adapt to evolving production demands.
4 METHODOLOGY
This section outlines the methodology used to re-
design the industrial control system architecture at
Demcon. The approach involved migrating upper-
level control modules to a .NET environment while
keeping lower-level control within PLCs. Communi-
cation between the two levels was facilitated by an
MQTT broker, with the integration of Sparkplug B
to extend MQTT functionality for real-time data ex-
change.
4.1 System Architecture Redesign
The system follows a hybrid architecture, where most
ISA-88 abstraction layers were migrated from the
real-time PLC system to .NET. Communication be-
tween the real-time and non-real-time components is
facilitated by an MQTT broker (Figure 4). This shift
addresses PLC memory and processing limitations,
enabling more complex control logic and real-time
data processing.
The modular architecture divides the system into
Optimising IIoT Control Systems at Demcon: Integrating MQTT, Sparkplug B, and ISA-88 for Unified Automation
353

Figure 2: Diagram of the BRIX Controller built following the ISA88 standard.
independent components: PLC modules handle real-
time control and lower-level tasks, while .NET mod-
ules manage upper-level logic and dynamic control
flows. The MQTT broker acts as the central mes-
saging hub, enabling publish/subscribe communica-
tion between modules. This modular approach en-
hances scalability, simplifies system updates, ensures
fault isolation, and supports future expansions. Fig-
ure 3 illustrates these components and their interde-
pendencies.
Figure 3: Modular view of .NET modules within the non-
real-time controller (zoom-in representation from Fig 3).
A key part of the intervention was the implemen-
tation of a PLC-level broker (highlighted in yellow
in Figure 4), which serves as a proof of concept
for integration into the broader BRIX broker archi-
tecture. This will provide a more extensive unified
namespace, enhancing flexibility and communication
across the control system.
The system architecture shifted from a cycle-
based PLC approach to an event-driven model in the
.NET modules, where each subprocess triggers the
next immediately. Physical elements change state or
send notifications through the event system, enabling
instant reactions to changes and maintaining contin-
uous operation. This transition replaces fixed cycles
with event-driven behavior, making the system more
dynamic and closer to real-time operation.
4.2 Communication Protocol: MQTT
and Sparkplug B
MQTT, augmented by Sparkplug B, was imple-
mented to enable efficient real-time communication
between the .NET modules, PLCs, and the MQTT
broker. MQTT was chosen for its lightweight pub-
lish/subscribe model, ideal for low-bandwidth en-
vironments. Sparkplug B was used to standardize
data formats, organize data into a hierarchical topic
namespace, and support device lifecycle management
through ”birth” and ”death” messages. These features
helped improve system reliability. However, Spark-
plug B was found to be incompatible with the existing
system due to its rigid structure, limiting its utility in
this specific case.
4.3 Data Monitoring and Collection
Real-time data monitoring was implemented using
MQTT Explorer to validate the redesigned archi-
tecture. The tool visualized the data flow between
the .NET modules, PLCs, and the MQTT broker,
ensuring efficient communication through a Unified
Namespace (UNS) based on system constraints and
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Figure 4: BRIX hybrid controller: Composition of ISA-88 abstraction modules, illustrating the division between real-time
and non-real-time components. This zoomed-in view highlights the specific components and interactions within the BRIX
controllers as shown in Figure 1.
inter-module relationships. The data streams included
operational data from sensors, actuators, and PLCs,
system status updates through lifecycle events, and
control commands from .NET modules managing
physical processes. Figure 5 shows the topic hierar-
chy used for monitoring, structured by module loca-
tion and data scope.
Figure 5: Screenshot taken from MQTT Explorer during
system monitoring.
5 RESULTS AND EVALUATION
The project aimed to assess the feasibility of us-
ing MQTT and Sparkplug B for IIoT communication
while designing a scalable control system. These ob-
jectives were successfully met, with MQTT enabling
efficient communication. However, Sparkplug B ex-
hibited limitations due to its rigid structure. The fol-
lowing analysis evaluates system functionality, per-
formance, communication efficiency, and the integra-
tion feasibility of MQTT and Sparkplug B.
5.1 System Functionality and
Performance
Transitioning from a PLC-based to a hybrid architec-
ture combining PLCs and .NET modules enhanced
system flexibility and scalability while retaining es-
sential real-time control for industrial automation.
This aligns with the broader trend of integrating
legacy systems with modern architectures to meet In-
dustry 4.0 and IIoT requirements (Sheetal M. Solanki,
2023; Mohammed Saleem et al., 2024).
The modular design of the .NET-based architec-
ture greatly improved flexibility, allowing for inde-
pendent development of control modules. This facil-
itated easier updates and maintenance while enabling
seamless future expansions without disrupting the
Optimising IIoT Control Systems at Demcon: Integrating MQTT, Sparkplug B, and ISA-88 for Unified Automation
355

system’s existing functionality. In IIoT contexts, such
modularity is critical for scaling and reconfiguring
systems to meet evolving industrial demands (Garcia
et al., 2022). Additionally, the event-driven model
in .NET provided dynamic control, making the sys-
tem more responsive compared to the cyclic execu-
tion inherent in traditional PLCs. This adaptability is
a cornerstone of Industry 4.0, where operational effi-
ciency depends on swift responses to changing condi-
tions (Walas and Redchuk, 2021).
Scalability was also a significant improvement,
supported by MQTT’s publish/subscribe model. This
architecture efficiently managed multiple devices and
data streams, minimising communication overhead.
The lightweight nature of MQTT messaging ensured
that modules only subscribed to relevant topics, re-
ducing unnecessary data exchange and optimising
communication efficiency. This characteristic makes
MQTT particularly suitable for resource-constrained
environments (G. Reddy, 2017).
5.2 Communication Efficiency
The integration of MQTT resulted in noticeable im-
provements in communication efficiency. By utilising
its publish/subscribe model, the system facilitated im-
mediate data transmission between publishers, such
as PLCs and sensors, and subscribers, such as .NET
modules. This mechanism ensured consistently low
latency, with most messages being delivered within
100 milliseconds. Such performance is essential for
industrial applications requiring real-time control and
aligns with findings in other studies that highlight
MQTT’s advantages over alternative protocols such
as CoAP and OPC UA (Rocha et al., 2019).
5.3 Feasibility of MQTT and Sparkplug
B in IIoT Systems
The study examined the feasibility of integrating
MQTT and Sparkplug B within an IIoT framework:
MQTT demonstrated high effectiveness in support-
ing real-time communication, ensuring tight interac-
tion between various system components. Spark-
plug B proved less suitable due to its rigid payload
structure and strict device-oriented namespace rules.
These limitations introduced redundancy and com-
plexity, rather than enhancing scalability or data man-
agement. While the system benefited from MQTT’s
low-latency data exchange, which supported real-time
monitoring and control, Sparkplug B’s inflexible for-
mat hindered its broader applicability (De Minicis
et al., 2014; Neugschwandtner et al., 2013).
5.4 Limitations and Challenges
Despite the successes, the system faced several lim-
itations. One significant challenge was the compati-
bility of Sparkplug B, whose rigid structure and strict
namespace rules were poorly suited to the PLC archi-
tecture. This led to increased redundancy and com-
plexity without providing notable improvements in
data management. Another limitation was the lack of
real-world testing. The system relied on static recipes
and simulated data, restricting its exposure to dy-
namic, real-world industrial conditions. To fully eval-
uate long-term performance, testing in practical envi-
ronments is necessary (Walas and Redchuk, 2021).
Furthermore, this study focused on developing a
proof-of-concept rather than a fully implemented so-
lution, meaning there are no direct performance com-
parisons to traditional PLC systems at this stage. The
results presented here demonstrate the feasibility of
the proposed hybrid architecture and communication
protocols, serving as a foundation for future research.
The integration of MQTT showed clear benefits in
communication efficiency, while the challenges iden-
tified with Sparkplug B suggest areas for further de-
velopment. Future work will focus on completing
the migration of control modules to .NET, optimizing
system performance, and conducting real-world test-
ing to validate the system’s scalability and robustness
in industrial environments.
6 DISCUSSION AND LESSONS
LEARNT
The results of the system redesign highlight the feasi-
bility of integrating MQTT and Sparkplug B into in-
dustrial control architectures. This section explores
the broader implications of the findings, lessons from
the system redesign, and the potential for applying the
architecture to other industrial contexts.
6.1 Key Takeaways
The transition from a traditional PLC-centric system
to a hybrid architecture provided insights into the
challenges and opportunities of IIoT-based industrial
automation. Combining PLCs with .NET-based con-
trol modules proved advantageous, retaining the re-
liability of PLCs for real-time control while lever-
aging the flexibility of .NET for higher-level logic.
This hybrid approach enabled a more adaptive sys-
tem without compromising reliability, aligning with
industry trends towards scalable and adaptable con-
trol systems (Walas and Redchuk, 2021).
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Figure 6: Enhanced communication in BRIX controllers enabled by MQTT and a unified namespace. Red lines represent new
communication channels; black lines depict improved existing connections, derived from legacy architecture.
Standardised communication protocols also
played a vital role, as evidenced by the effectiveness
of MQTT. The adoption of MQTT facilitated seam-
less, scalable communication across diverse devices
and platforms. Literature supports this observation,
noting that protocols like MQTT and Sparkplug
B simplify the management of complex systems
while reducing development and maintenance
efforts (Iglesias-Urkia et al., 2017).
6.2 Applicability to Other Industries
and Future Extensions
This study’s findings are applicable beyond Dem-
con’s systems, offering a versatile model for indus-
tries adopting IIoT technologies, including energy,
healthcare, and logistics. The architectural design,
particularly the use of MQTT and Sparkplug B, aligns
well with requirements in smart factories and dis-
tributed energy systems, where real-time data ex-
change is crucial (Koprov et al., 2022). Addition-
ally, the architecture provides a foundation for inte-
grating advanced technologies, such as AI for predic-
tive maintenance and edge computing for enhanced
real-time processing. As IIoT evolves, these features
position the architecture to address emerging trends
in Industry 4.0 (Waghanna et al., 2024).
7 CONCLUSION
This study presents the successful redesign of a PLC-
based control system into a flexible scalable hybrid
architecture using MQTT and Sparkplug B. The sys-
tem combines PLCs’ real-time control with the dy-
namic, event-driven nature of .NET modules, improv-
ing scalability, communication efficiency, and modu-
larity. MQTT enabled efficient communication, while
Sparkplug B standardized data, allowing seamless in-
tegration across system components and supporting
the evolving demands of industrial automation.
While the architecture was effective in controlled
testing, challenges with Sparkplug B compatibility
and limited real-world testing show areas for further
investigation. The architecture has broader potential
for industries like manufacturing, energy, healthcare,
and logistics, which could benefit from the flexibility
and efficiency of IIoT-based control systems.
In conclusion, this research laid the groundwork
for further development of hybrid architectures at
Demcon, offering a path for integrating modern com-
munication protocols and real-time data processing
into traditional manufacturing environments.
Optimising IIoT Control Systems at Demcon: Integrating MQTT, Sparkplug B, and ISA-88 for Unified Automation
357

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