Navigating industrial access control: a complete guide

What is industrial access control?

Industrial access control refers to a combination of smart technologies and best practices designed to manage and regulate access to high-risk areas within industrial facilities. 

They safeguard valuable assets, hazardous materials and complex machinery from unauthorized access, while preventing untrained or unequipped individuals from entering dangerous work environments.

Industry-specific assets that must be protected by industrial access control systems include:

• Hazardous materials: the chemical manufacturing industry alone produces over 22 million tons of hazardous materials annually. In 2023, over 270 hazardous chemical incidents were reported in the U.S., many of which could have been mitigated by stricter access controls. 
• Industrial machinery: heavy equipment theft costs construction companies an estimated $400 million annually, while machinery accidents result in approximately 800 fatalities and around 18,000 injuriesat industrial sites across the U.S. each year. 
• High-risk worksites: entry to high-risk areas like active construction sites, chemical storage facilities, equipment maintenance bays and research labs must be strictly controlled to mitigate incidents of theft and serious accidents. 
• Intellectual property: intellectual property theft costs the U.S. economy around 1% to 3% of its GDP annually, or between $180 billion to $540 billion. Industrial companies frequently hold proprietary technologies and research, making them prime targets for such theft.

The benefits of industrial access control systems

The development and ongoing optimization of industrial access control systems offer several significant benefits for businesses in this sector. Business owners and facility management teams can enhance safety and security in the following key areas: 

Asset protection

Industrial, manufacturing and factory access control systems can help businesses to prevent the misuse of valuable equipment and materials. Managers can limit the risks of internal and external theft by ensuring only authorized employees are granted access to high-risk assets. 

Occupational safety

Industrial access control systems help ensure dangerous areas of worksites are secured at all times, reducing the risk of unauthorized employees or guests accidentally endangering themselves. Access permissions can also be tailored to employees’ qualifications and certifications, meaning only workers with required training can access hazardous areas and dangerous equipment. 

Regulatory compliance

Restricting access to dangerous areas and machinery can help facility managers enforce internal safety rules and external regulations. Industrial access control systems can automatically limit the number of people in restricted areas, ensure that staff are not subjected to unsafe work schedules and help businesses maintain standards established by regulatory bodies.

Operational efficiency

Access control security systems collect data that can improve operational efficiency across industrial worksites. For example, manufacturing facility access control systems can provide start and end times for daily processes based on when employees enter and exit facilities. Organizations can then analyze this data to improve operations.

Cybersecurity

Cyberattacks targeting businesses in the manufacturing and industrial sectors have increased by 105% in recent years as cyber threat actors seek access to sensitive information or demand high ransom payments. Physical access control systems limit access to critical infrastructure, like servers and routers, while digital access control solutions help mitigate the risk of unauthorized access to computer systems and cloud-based data.

Types of industrial access control solutions

The industrial access control industry offers facility managers a variety of security technologies and tools to manage access to both physical and digital assets. Customized combinations of access control solutions can help ensure comprehensive protection of all locations and equipment. Common types of industrial access control systems include: 

Perimeter security systems

Access control technologies installed around the boundaries of industrial facilities act as a first line of defense against intrusions in perimeter security. These technologies can include physical barriers, turnstiles, smart locks and gates. Some systems may require employees to present physical or digital credentials to gain entry, while others rely on security guards to manage access requests.

Token-based access control

Industrial access control readers at facility entrances and internal entry points automatically prevent unauthorized access. Employees and verified guests must present personalized credentials, such as radio-frequency identification (RFID) cards, key fobs or mobile apps, to enter restricted areas.

Biometric industrial access control

Biometric credentials in industrial access control systems provide an extra layer of protection to restrict access to high-security locations like research labs and chemical storage facilities. Credentials can include biometric indicators, such as iris scans, fingerprints and facial recognition data, and are often used in conjunction with tokens to enhance security and prevent breaches from lost or stolen credentials.

Video security access systems

Commercial security cameras can enhance industrial access control systems by providing security teams with visual identification capabilities. Pan-tilt-zoom (PTZ) cameras can be deployed to detect and follow objects in target areas, ensuring comprehensive coverage. Additionally, video analytics software can analyze biometric data and identify anomalies that may impact access decisions.

Digital access control solutions

As more industrial organizations embrace digital technologies, such as cloud computing and the Industrial Internet of Things (IIoT), it becomes increasingly important to enhance cybersecurity measures. Digital industrial access control solutions encompass password protections, multi-factor authentication, firewalls and zero-trust policies to restrict access to digital systems.

Seven tips for implementing industrial access control systems 

Thorough planning and careful consideration are essential in the development and implementation of industrial access control systems to effectively protect assets, equipment and personnel. Facility managers and security professionals should collaborate to create intuitive systems tailored to specific needs. Here are seven tips for successfully implementing industrial access control systems: 

1. Conduct a full-site risk assessment

The entire facility should be evaluated to identify all necessary and potential access points for the effective implementation of access control technologies. Physical penetration tests should be conducted to assess the performance of existing industrial security systems and identify any vulnerabilities that could be exploited. Key sensitive locations to focus on include:

• Access roads
• Perimeter fences
• Reception areas
• Loading bays
• Storage facilities
• Server rooms
• Production plants
• Research and development (R&D) laboratories

2. Select appropriate credential types

Different credentials are suited to specific areas. For example, low-risk locations like reception areas can be secured with user-friendly and cost-effective mobile credentials or key fobs to minimize congestion during regular operations. In contrast, high-risk areas like R&D labs and production plants might require advanced biometric and multi-factor credentials for enhanced security.

3. Consider installation requirements

Industrial access control readers and supporting technologies, such as IP security cameras, must be connected to power sources and data networks. It’s important to assess whether the existing wiring infrastructure can support these new systems. If it cannot, consider the feasibility of installing new cables from both logistical and financial perspectives. Alternatively, exploring secure wireless access control and security solutions may be worthwhile. 

4. Assign roles to credentials

Access control systems can be implemented to automate certain aspects of industrial security. Roles assigned to credentials can automatically restrict site-wide access to high-risk areas, ensuring that only qualified personnel can enter certain locations. This helps mitigate the risk of credential misuse, reducing the potential for serious accidents and security breaches.

5. Explore wider security integrations

Industrial access control systems can be enhanced through integrations with wider security systems. Video security systems can record and flag footage of suspicious access attempts, while integrated alarms can sound in response to tampering attempts. A unified cloud management platform allows security teams to view live feeds and receive alerts remotely from any secure smart device.

6. Develop emergency response plans

Despite the precautions taken to prevent security breaches, issues can still arise. It is essential to develop comprehensive plans that outline responses to credential misuse, theft and physical security breaches. This includes procedures for revoking permissions, resetting industrial access control systems and safe evacuation protocols for employees and visitors. 

7. Regularly maintain access control systems

Facility managers must conduct regular maintenance routines to ensure systems operate effectively and protect against emerging physical and cyber threats. This should involve inspecting hardware for damage, updating software, reviewing access records and performing diagnostic tests to support the safe operation of industrial access control solutions.

Challenges of access control in industrial sites

With the complexity of industrial operations, implementing and safely operating access control systems can be challenging. For facility managers and security professionals looking to create customized industrial access control installations, here are some challenges to consider, along with potential solutions:

• Managing access levels: the severity of safety and security risks can vary significantly across different areas of industrial sites, so not all credential holders should have access to every location. Role-based access models and biometric credentials enable admins to manage access levels from a centralized digital platform.
• Controlling visitor access: contractors, inspectors, students and visitors often attend industrial sites for various reasons, with each requiring different levels of access. Time-based mobile credentials can be issued to guests’ personal smart devices through an industrial visitor management system to give them temporary access to specific areas.
• Mitigating cyberattacks: industrial sites often use connected technologies like IIoT devices, which can be vulnerable to cyberattacks. Industrial access control systems should be secured with firewalls, endpoint detection and response (EDR), encryption and other cybersecurity measures to mitigate the risk of disruption.
• Updating legacy controls: updating legacy systems can be time-consuming and costly, so it may be beneficial to perform updates in stages. Teams should assess existing wiring and network infrastructure to identify compatible new technologies and consider using secure wireless industrial access control readers in specific areas.

Examples of successful industrial access control implementations

Below are some real-world examples of how customized industrial access control systems can improve security and convenience in high-risk industrial environments:

Precision Science: flexible, touchless access control 

The manufacturing, packaging and solutions campus at Precision Science uses a customized manufacturing plant access control system designed to provide flexible permissions to users via mobile credentials and encrypted RFID key cards. Security staff can view and adjust user permissions remotely in real-time to help ensure access levels are consistently managed.

Invia Robotics: cloud-based, mobile access control

As a 24-hour facility, Invia Robotics relies on a cloud-based industrial access control system to enable security staff to issue and track credentials around the clock. The system uses automated identity management software to ensure workers have access to required areas at all times, eliminating the security risks associated with transferring physical credentials.

INDEVCO: integrated video security and access control

IINDEVCO assists its security staff in managing access requests and investigating suspicious events through the integration of video security and access control systems. Live feeds of high-risk areas are accessible 24/7 via a cloud management platform, with alerts set to notify managers of potential risks, such as unauthorized individuals entering restricted areas.

Key takeaways

Access control is fundamental to effective digital and physical security planning for organizations across all industries. However, businesses in the industrial sector face unique safety and security risks that typical access control installations may not fully address.

Industrial access control systems must be user-friendly, flexible and capable of issuing credentials for varying levels of access permissions. Advanced credentials should be used to secure high-risk areas, while provisions must be made to manage temporary access for contractors, visitors and contract workers. By considering the guidance outlined above, organizations can develop tailored and effective industrial access control systems.