Case Study: Reliable Connectivity for Manufacturing | Benlycos

Background

The cost of a high-impact IT outage is over ₹ 8.8 crore per hour for 45% of Indian firms. For a manufacturing company that produces essential materials, an available and reliable network is imperative. When a unit loses connectivity even for a minute, it impacts automated systems, supply chain management, real-time monitoring, data synchronisation, and internal and external communication. This is a huge operational risk. This case study explores how one of India’s largest building material manufacturers secured a trusted backup for their digital infrastructure.

When a Facility Goes Off the Grid

Operating massive industrial plants requires precision. However, relying on a single wired ISP created a dangerous vulnerability. When primary lines went down due to local infrastructure issues, the plant went “off the grid.”

This lack of connectivity severed the link between the factory floor and the central ERP systems. Automated machinery lost coordination, inventory tracking stalled, and critical safety monitoring systems were compromised, leading to profound financial and operational setbacks.

Edge by Benlycos network management dashboard

The Benlycos Solution: Zifilink 5X

To combat these severe outages, the manufacturer deployed the Zifilink 5X bonding router. Designed for demanding environments, the Zifilink 5X allowed the plants to aggregate multiple diverse internet sources into a single, unbreakable connection.

By combining cellular 4G/5G connections with any available broadband lines, the Zifilink 5X created a fault-tolerant network. If one connection dropped, the traffic seamlessly and instantly migrated to the remaining active links, ensuring the automated processes never skipped a beat.

The Implementation

Rapid deployment of Zifilink 5X routers across distributed manufacturing plants.
Aggregation of multiple cellular (4G/5G) and broadband connections for maximum bandwidth.
Configuration of intelligent traffic steering to prioritize ERP and automated machinery data.
Seamless integration with existing enterprise firewalls and IT infrastructure.
Centralized visibility and management via the secure cloud dashboard.

Results and Impact

Achieved 99.99% network uptime across all deployed manufacturing facilities.
Eliminated millions in potential losses from IT-related manufacturing downtime.
Ensured continuous data synchronization between plant floors and the central supply chain network.
Drastically reduced IT troubleshooting time with remote dashboard management.
Provided a scalable connectivity template for future plant expansions.

Why Benlycos?

Benlycos specializes in engineering mission-critical connectivity solutions that keep industries moving. Our bonding technology is built to withstand the toughest network environments, providing unparalleled uptime and peace of mind.

Click here to learn more about our solutions, email us at sales@benlycos.com, call +91 9590114040, or visit benlycos.com.