Software-Defined Distributed Control for Process Industries

Schneider Electric has launched EcoStruxure™ Foxboro Software Defined Automation (SDA), positioning it as the industry’s first open, software-defined distributed control system designed for hybrid and process industry operations.

Why software-defined control is emerging
Distributed control systems have traditionally relied on tightly coupled hardware and software architectures. While this approach has delivered deterministic control and high availability, it has also led to costly upgrades, limited interoperability and increasing obsolescence risks. As plants face digitalization pressures, cybersecurity requirements and workforce constraints, these limitations have become more pronounced.

Schneider Electric cites industry research conducted with Omdia indicating that closed automation systems cost mid-sized industrial companies an estimated 7.5% of annual revenue through downtime, inefficiencies and retrofit-driven compliance efforts. This economic impact has accelerated interest in open, modular automation architectures.

Decoupling hardware and software
EcoStruxure Foxboro SDA is built on a software-defined architecture that separates control software from the underlying hardware. This decoupling allows users to retain existing assets while introducing new functionality incrementally, reducing modernization risk and capital intensity.

The system is powered by EcoStruxure Automation Expert, Schneider Electric’s automation platform based on IEC 61499 principles. This enables distributed applications to run independently of specific hardware, supporting fit-for-purpose configurations across controllers, edge devices and virtualized environments.

Open architecture and interoperability
Foxboro SDA is designed as an open system, enabling interoperability with third-party hardware and software. Vendor independence allows operators to adapt architectures as operational requirements evolve, rather than being constrained by proprietary platforms.

From an operational perspective, this openness supports faster deployment, easier system expansion and simplified integration with advanced analytics, artificial intelligence and machine learning applications. These capabilities are increasingly relevant for process optimization, energy efficiency and predictive maintenance.

Cybersecurity and compliance considerations
Cybersecurity is addressed through secure-by-design principles and alignment with IEC 62443-3-3 requirements. By embedding cybersecurity into the architecture rather than treating it as an add-on, Foxboro SDA is positioned to support IT/OT convergence while maintaining control system integrity.

This approach also simplifies compliance management across the system lifecycle, from engineering and commissioning through operations and maintenance.

Operational and lifecycle impacts
By maintaining data continuity across design, production and maintenance phases, Foxboro SDA supports consistent information models throughout the plant lifecycle. This continuity enables automated workflows, improved product quality and more informed, real-time operational decision-making.

Avoiding forced hardware refresh cycles helps reduce both capital expenditure and unplanned downtime. Predictive maintenance capabilities further contribute to lower operating costs and improved asset availability.

Implications for hybrid and process industries
For industries such as chemicals, energy, life sciences and hybrid manufacturing, Foxboro SDA represents a shift toward control systems that can evolve alongside business and regulatory demands. The software-defined approach enables gradual modernization rather than disruptive system replacement, while preserving the reliability associated with traditional Foxboro DCS installations.

As industrial automation moves toward more open, data-centric architectures, Foxboro SDA illustrates how distributed control can be re-engineered to support future digital strategies without compromising deterministic performance or availability.