Testing and Private Networks for Manufacturing

Private LTE and 5G operate on licensed or lightly licensed spectrum and offer deterministic latency, broader coverage with fewer access points, better support for high device density and mobility, and can be architected to meet the performance requirements of OT systems. Industrial deployments have documented significant outcomes: Tesla eliminated AGV stoppages at its Gigafactory Texas facility, and Peel Ports achieved a tenfold increase in network performance at the Port of Liverpool's metal-heavy environment, which had previously hindered Wi-Fi connectivity.4 Industrial giants experiencing patchy Wi-Fi coverage, cabling-related inflexibility, and network scalability limitations at their facilities are now among the leading adopters of private 5G.2

A private LTE/5G network is a cellular network deployed and operated by a single organisation for its own use, rather than shared public carrier infrastructure. The operator controls the spectrum, hardware, coverage footprint, security policies, and QoS configuration. By the end of Q3 2025, GSA had identified 1,907 organisations worldwide deploying private mobile networks across 84 countries, with customer references growing at a CAGR of 34% since 2020.1 Manufacturing is the leading sector by number of deployments.1

The main barriers are: spectrum availability and licensing (varies by jurisdiction); integration complexity between OT systems and new cellular infrastructure; total cost of ownership concerns compared to incumbent Wi-Fi; and lack of internal cellular expertise.3 These are best addressed through a phased approach — starting with a pilot deployment in a defined area with a limited device set, validating performance against specific use cases before expanding. Pre-deployment device testing with the Pico5G Series reduces integration risk, while the PicoNet's integrated radio-and-core architecture lowers deployment complexity compared to traditional multi-vendor cellular infrastructure.

Applications that benefit most require mobility, high device density, or performance guarantees that Wi-Fi cannot reliably deliver: autonomous guided vehicles (AGVs) and mobile robotics requiring continuous low-latency links as they move around a facility; high-density sensor networks for predictive maintenance and asset tracking; real-time video monitoring for quality control and safety; remote operation of machinery and cranes; worker safety systems requiring reliable uplink; and OT/SCADA backhaul in facilities where wired connectivity is impractical.2,4

The Pico5G Series is used to validate industrial IoT devices — sensors, gateways, PLCs with cellular interfaces, AGV communication modules, handheld terminals, and machine connectivity adapters — against a controlled LTE or 5G network before they are deployed on the factory floor. Engineers can test attach behaviour, data throughput, latency under load, reconnection after signal loss, and power consumption profiles. This reduces the risk of discovering connectivity issues during production deployment, where troubleshooting costs are significantly higher than in a lab.

Yes. The Pico5G Series supports channel simulation per 3GPP 36.101 and 38.141 specifications, allowing engineers to introduce signal impairments — interference, path loss, bandwidth reduction, packet loss — that reflect the RF conditions found in factories with high-power motors, metallic enclosures, arc welding equipment, and other industrial noise sources. Testing devices against these simulated conditions in the lab builds confidence that connectivity will perform as expected in the actual manufacturing environment.

The PicoNet is a private LTE/5G small cell solution that integrates the radio access network and core network in a single unit, simplifying deployment and reducing infrastructure footprint. It supports LTE and 5G NR across a broad range of frequency bands, delivers up to 50 MHz bandwidth with 2×2 MIMO and up to 2×10 W transmit power for robust indoor and outdoor coverage. On the factory floor, PicoNet units can be positioned to provide contiguous coverage across production zones, warehouses, and loading areas, with the network operated entirely under the facility owner's control.

Because the PicoNet is privately operated, its security policies, QoS rules, and routing can be configured to keep OT traffic separated from corporate IT networks while still enabling integration where required. The PicoNet runs on Ubuntu OS, enabling direct deployment of lightweight edge applications on the same infrastructure. This converged architecture reduces the number of separate network segments and gateways that typically complicate OT/IT integration.

A practical approach has three stages. First, use a Pico5G model in the lab to validate the specific devices, sensors, or gateways planned for the deployment. Second, deploy a PicoNet pilot covering a single production zone or warehouse area, connect the validated devices, and measure performance against the target use case. Third, expand coverage and device count based on validated results. This phased approach mirrors the pattern adopted by many of the 1,907 organisations now deploying private networks globally, which increasingly show a shift from single-site pilots to multi-site operational rollouts.1

Yes. Nutaq offers solutions across the full manufacturing connectivity lifecycle. The Pico5G Series supports device validation from early development through ongoing regression testing. The PicoNet supports pilot and operational private LTE/5G deployments at industrial sites. Both products are supported with training, configuration assistance, and support packages. Contact Nutaq to discuss your project.