In a Expert Talk by ONDESO, our CEO Silvan Pfirrmann (PLUS4DATA)
together with Peter Lukesch (CEO, ONDESO) talked about
why OT backups often do not work in an emergency – and how companies
can significantly reduce the risk of production downtime.
Key statements from the conversation
- Backups exist, but are not findable
- A backup is not automatically a restorable backup – only the restore test counts
- IT is secured, OT often is not
- Cyberattacks make validated backups indispensable
- With clear processes, restores in minutes are possible
Central message
A backup is only effective if it is complete, structured, tested and in an emergency quickly restorable.
Watch the full expert talk:
Secure and restore OT assets – reproducible
FAQ – Expert Talk “Backup & Recovery in OT”
What was the reason for the Expert Talk on OT backup & recovery?
What was the reason for the Expert Talk on OT backup & recovery?
In the Expert Talk, Silvan Pfirrmann (CEO, PLUS4DATA) and Peter Lukesch (CEO, ONDESO) spoke from practical experience about why backup strategies in OT often fail – even though backups exist – and what consequences this has for production availability and business continuity.
Why are traditional IT backup concepts not sufficient in OT?
Because production environments consist of significantly more components than traditional IT systems. In addition to industrial PCs, PLCs, controllers, robotics and their dependencies play a central role. If only part of it is secured, production may still not be able to restart in an emergency.
What typical backup problems occur in OT according to the conversation?
n the Expert Talk, three recurring cases were described:
No backup exists
A backup exists, but is not findable, too old, or not clearly versioned
The backup was found, but the restore process is unclear or not documented
These situations lead to long downtime in an emergency.
Why is “Backup ≠ Restore” a central topic in the Expert Talk?
According to the conversation, a backup is only reliable once it has actually been restored. Problems such as missing drivers, incomplete images or incompatible system states only become apparent during the restore. An untested backup therefore only provides a false sense of security.
What role do cyberattacks play in OT backup & recovery?
Cyberattacks significantly increase the pressure. In the talk, it was emphasized that backups can also be compromised if they are not checked or validated. If an infected backup is restored, the malware is reintroduced into the system.
How long does a restore take in practice?
With good organization, clear processes and tested backups, restoring individual controllers or systems can take minutes to less than an hour. Without structure and preparation, the same process can take hours or days.
What factors most often delay the restore?
In the conversation, the following points were mentioned, among others:
- Backups are distributed across USB sticks, laptops or programming devices
- missing or outdated restore instructions
different device states, firmware versions or legacy systems - slow transfer paths during restore
These factors are often underestimated in everyday operations.
Why is OT backup often neglected from an organizational perspective?
A main reason is the unclear responsibility between IT, OT, maintenance and management. Responsibility for availability and budget often diverge. In an emergency, however, this separation does not help anyone – production still stops.
What do the speakers recommend as a first step?
Do not wait for the perfect overall concept, but:
- identify OT assets
- prioritize critical components
- start step by step with structured backup
Every secured component reduces the risk – even if not everything is perfect yet.
What is the importance of documentation and restore instructions?
They are essential. In the Expert Talk, it was recommended to keep clear, ideally illustrated restore instructions available. In stressful situations, simple, clearly structured steps help more than extensive documents.
What is the central message of the Expert Talk?
An OT backup is only effective if it:
- is complete
- is stored in a structured way
- is regularly tested
- and can be restored under real conditions
Everything else increases the risk of unplanned production downtime.
