Patch Management and Legacy Systems in the Realm of OT Cyber Security

Legacy OT systems are the backbone of many industrial operations, but their age and design make them difficult to secure. Traditional patch management practices often fall short, as critical systems cannot be taken offline for updates without disrupting production.

According to TXOne, cyber attacks targeting legacy systems in operational technology (OT) environments can inflict severe financial and operational damage, with costs often far exceeding those of typical IT breaches. According to their findings, 43% of organizations with legacy OT systems experienced a cyber incident within the past year, with incidents ranging from malware and ransomware to unauthorized access and system disruptions. 

The financial impact of such attacks is substantial with one  high-profile case standing out, a $450 million loss incurred by MKS Instruments in February 2023, highlighting the potential for catastrophic losses when legacy systems are compromised. Beyond direct financial costs, attacks on legacy OT can halt production, endanger worker safety, disrupt supply chains, and erode customer trust—consequences that are especially pronounced in industries reliant on continuous, non-stop operations.

These risks underscore the urgent need for robust security measures tailored to the unique challenges of aging industrial infrastructure.

Some of the key challenges include:

• Vendor Support Limitations: Many legacy systems are no longer supported by their original manufacturers.

• Compatibility Issues: Patches may conflict with custom configurations or proprietary software and create operational disruptions.

• Operational Constraints: Downtime for patching is often unacceptable in mission-critical environments.

• Costs: Many organizations have financial constraints that prevent them from buying new systems (with already embedded cyber security measures).

• “Don’t Touch if it Ain’t Broken”: Organizations are reluctant to replace systems that work and get the job done.

To address these challenges, organizations should consider:

• Virtual Patching: Deploy intrusion prevention systems to block exploits targeting unpatched vulnerabilities.

• Network Segmentation: Isolate legacy systems to limit their exposure to threats.

• Compensating Controls: Implement additional security measures such as strict access controls and continuous monitoring.

• Risk-Based Prioritization: Focus patching efforts on the most critical vulnerabilities first.

• The Human Element: Train and engage staff to elevate organizational awareness. This will help avoid critical human errors. 

  
  

RubyComm’s unique expertise in securing legacy environments helps clients protect their most valuable assets without compromising operational continuity.

About RubyComm: RubyComm delivers tailored operational technology (OT) cybersecurity solutions for industrial environments where standard products fall short. Based in Israel with a U.S. presence, we secure critical systems for industrial manufacturers, infrastructure operators, medical equipment providers, energy producers, and smart building managers. Our competitive advantage lies in creating customized security architectures that address the specific challenges conventional solutions cannot: functionality limitations in specialized settings, complex operational environments requiring precision approaches, prohibitive pricing structures, and technical expertise gaps within client organizations. Unlike one-size-fits-all offerings, RubyComm's solutions maintain operational efficiency while providing comprehensive protection, transforming security from a product purchase into a strategic partnership. Our team of specialists is strategically positioned to scale our proven methodology, meeting the rapidly growing demand for sophisticated OT security across vital sectors worldwide.