Why Linux Is Gaining Ground Over Windows in Industrial Environments
Introduction
In the world of industrial automation and operational technology (OT), the choice of an operating system is more than a matter of preference — it’s about stability, security, control, and long-term sustainability. For decades, Microsoft Windows has been the dominant platform in factories, process control rooms, and SCADA systems. But in recent years, Linux has increasingly drawn attention from manufacturers, system integrators, and industrial engineers alike.
Why is Linux gaining ground in industrial systems today? In this post, we’ll dive into the technical, strategic, and economic factors contributing to this shift. Whether you’re an automation engineer, OT manager, or a C-level decision-maker, understanding the reasons behind this trend can help you make smarter infrastructure decisions.
Table of Contents
- The Legacy of Windows in Industrial Systems
- Why Linux is Attracting Industry Attention Today
- Key Technical Advantages of Linux in Industrial Use
- Security, Stability, and Licensing Benefits
- Industry Applications and Real-World Examples
- When to Choose Linux Over Windows
- Challenges in Moving to Linux
- Conclusion: The Future of Linux in Industrial Systems
1. The Legacy of Windows in Industrial Systems
Historically, Windows-based HMI, SCADA, and DCS systems have ruled industrial control environments. Vendors like Rockwell Automation, Siemens, Honeywell, and Schneider Electric built user interfaces and control tools around Windows frameworks (e.g., .NET, Win32).
Why?
- Familiarity: Most engineers are trained on Windows.
- Vendor support: Proprietary software often mandates Windows.
- Ecosystem: Many legacy devices are Windows-dependent.
But this convenience came at a cost — mainly in security risks, licensing costs, and performance overhead.
2. Why Linux Is Attracting Industry Attention Today
Today’s industrial demands are shifting. There’s growing pressure for:
- Cybersecurity resilience
- Open standards compliance
- Edge computing and IIoT integration
- Cost optimization
In this evolving landscape, Linux is ticking the right boxes. Companies are reconsidering their OS platforms, especially for embedded systems, edge gateways, HMIs, and PLC runtimes.
3. Key Technical Advantages of Linux in Industrial Use
Here’s why Linux is now considered a technically superior option for many industrial applications:
| Feature | Linux | Windows |
|---|---|---|
| Real-Time Kernel Options | Yes (PREEMPT_RT, Xenomai) | Limited, only via Windows IoT RT |
| Resource Efficiency | Low footprint | Heavier footprint |
| Headless Operation | Native | Requires tweaking |
| Stability & Uptime | Years without reboot | Regular updates/reboots required |
| Package Control | Full control (YUM, APT) | Mostly vendor-locked |
Real-Time Capability
Linux with PREEMPT_RT patch or Xenomai is ideal for real-time control systems, where microsecond latency matters (robotics, CNC, process loops).
Hardware Control
Linux gives fine-grained control over hardware, essential for field buses (MODBUS, CAN, PROFINET) and industrial sensors.
4. Security, Stability, and Licensing Benefits
a. Security Advantages
- No bloatware or unnecessary background processes
- More transparent updates
- Community-patched vulnerabilities
- Linux systems often targeted less than Windows
With the rising threat of ransomware and supply chain attacks, Linux provides a smaller attack surface and customizable hardening options using tools like SELinux, AppArmor, and Firejail.
b. Licensing and Cost Benefits
Linux is open-source. No per-seat or CAL licensing fees — a major win for OEMs and large factories.
| Cost Area | Windows | Linux |
|---|---|---|
| OS License | $$$ | Free |
| Per Device License | Yes | No |
| Update Support | Requires licenses | Free for most distros |
c. Long-Term Support and Customization
Linux distros like Ubuntu LTS, Debian, Red Hat Enterprise Linux (RHEL), and Yocto-based builds offer stable, long-term releases customizable to exact industrial needs.
5. Industry Applications and Real-World Examples
Here are some scenarios where Linux is shining:
a. Edge Devices and Industrial Gateways
Devices like Siemens Industrial Edge, BeagleBone Black Industrial, and Advantech’s UNO series run embedded Linux for industrial communication, data logging, and predictive maintenance.
b. IIoT Platforms
IIoT frameworks like Kaa, ThingsBoard, Eclipse IoT, and Balena all support or are built on Linux. Docker, MQTT brokers, and InfluxDB run natively and efficiently on Linux.
c. PLC Runtime Systems
Codesys, a popular IEC 61131-3 compliant PLC runtime, supports Linux. This allows developers to create software-based PLCs on x86 or ARM hardware.
6. When to Choose Linux Over Windows
| Use Case | Recommended OS |
|---|---|
| Real-time control systems | Linux with PREEMPT_RT |
| IIoT / Edge computing | Linux |
| SCADA with Microsoft integration | Windows |
| Lightweight embedded systems | Linux |
| Legacy industrial networks | Windows (if driver support is limited) |
Choose Linux if:
- You require low-level hardware interaction.
- You want to reduce licensing costs.
- You are designing future-proof systems aligned with open standards.
Stick to Windows if:
- You’re locked into proprietary SCADA platforms.
- You depend on legacy OPC DA, ActiveX, or COM-based architectures.
7. Challenges in Moving to Linux
While Linux has many benefits, transitioning isn’t without hurdles:
- Steep learning curve for Windows-native engineers
- Limited driver support for some legacy industrial hardware
- Vendor ecosystem still Windows-centric
- Lack of standardization between Linux distributions
Solution: Partner with Linux-savvy automation vendors, adopt standardized distros like Ubuntu Core, and leverage cross-platform development environments.
8. Conclusion: The Future of Linux in Industrial Systems
As industries embrace digital transformation, open systems, and cybersecurity, Linux offers a flexible, secure, and cost-effective foundation. With growing support from major automation players and the rise of edge computing, Linux is no longer just for developers and hobbyists — it’s becoming mission-critical in OT environments.
✅ If you’re building a new plant, consider Linux-based platforms for edge, gateway, or control layers.
✅ If you’re modernizing legacy systems, explore hybrid strategies — run SCADA on Windows, but deploy data collectors and machine learning on Linux.
Frequently Asked Questions
1. Can Linux completely replace Windows in industrial automation?
Not entirely — many vendors still build Windows-only applications. However, Linux can complement or even lead in areas like IIoT, edge computing, and custom automation.
2. Is Linux harder to manage in OT?
Not necessarily. Once configured, Linux systems can run unattended for years. Centralized tools like Ansible, Puppet, or Foreman make mass updates and patching easier.
3. What’s a good Linux distro for industrial use?
- Ubuntu Core for embedded
- Debian for general industrial PCs
- RHEL or CentOS for enterprise support
- Yocto for highly customized embedded systems
Final Thought
In the battle between Windows and Linux in industrial automation, it’s not about winning or losing — it’s about the right tool for the right job. But if trends continue, Linux is poised to lead the next era of industrial innovation.