Corporate Network Modernization
How Valladares Tech transformed the infrastructure of a 350-employee manufacturing company in San Antonio, TX, achieving 98% less downtime.
⚠️ The Challenge
The client was experiencing an average of 47 hours/month of network outages that directly halted the production line at $2,400/hour in lost productivity. Their legacy flat network architecture lacked VLAN segmentation, making every broadcast storm cascade across the entire facility. Core hardware was End-of-Life with no patches since 2019.
- 47 hrs/month average network downtime costing ~$112,800/month
- Flat network with no OT/IT segmentation — a critical security risk
- CNC machines sharing the same VLAN as employee workstations
- EoL Cisco Catalyst 2960 switches, firmware from 2018
🔧 Our Solution
Our certified engineers designed a phased SD-WAN deployment with a dedicated OT/IT network segmentation strategy, allowing the factory floor to be isolated from corporate traffic without interrupting a single shift.
Network audit, VLAN design, hardware procurement
Parallel cabling, Meraki switch deployment after-hours
OT/IT cutover, FortiGate deployment, 72hr monitoring
Technologies Stack
Before vs. After
- ✗ 47 hrs/month downtime
- ✗ $112,800/month productivity loss
- ✗ Flat network, zero OT/IT separation
- ✗ 100Mbps bottleneck between plants
- ✓ <1 hr/month downtime (99.97% uptime)
- ✓ ~$110,000/month recovered in productivity
- ✓ 12 VLANs — complete OT/IT isolation
- ✓ 10Gbps fiber backbone between plants
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