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Protect formulations, keep the lab and PSM records available, guard the OT boundary

Chemical Manufacturing IT Services

A chemical plant can’t afford for its business network to become the path into its control systems, and it can’t afford to lose the records that prove it operates safely.

SOC 2 Aligned
Responsive Support
20+ Years Experience

At a glance

Formulations, batch records, LIMS results, certificates of analysis and process safety documentation all sit on IT systems that attackers target.

We run managed IT and cybersecurity for specialty, commodity and toll chemical manufacturers.

We harden the business network, build and monitor a defined boundary between IT and your DCS and historian, protect lab and quality systems, keep safety data sheets and PSM documents reachable when they’re needed, and back it all up so it can be restored.

Inside the control system, we work alongside your controls engineers and the DCS vendor. We serve plants in Texas and nationwide.

IT that keeps batches releasing, CoAs going out, the DCS walled off.

Managed IT and security for chemical plants, built around the line between business systems and the control room.

Chemical plant IT

A business network that never reaches the reactor

In a chemical plant, the stakes of an IT incident aren’t just lost orders. Lab results gate batch release, process safety records must be current, and the business network sits one misconfigured connection away from the control room. Here’s where that boundary weakens, what we put in place on the IT side, and how your operations team benefits.

01 · The pressure

Records, results and release all ride on IT

Operators run the process on the DCS, but almost everything around it lives on the business side. The lab enters results in LIMS before quality can release a batch and send the CoA. Engineers update P&IDs and management-of-change files. EHS keeps SDS libraries and PSM documentation current for audits and for the people who need them on shift. Customer orders, shipping papers and ERP inventory run on the same network. Lose it and product sits in tanks waiting.

  • LIMS results gate every batch release
  • PSM and MOC files must stay current
  • SDS access has to work on every shift

02 · How it breaks

The historian link nobody documented

Over the years, someone connected the plant historian so the business side could see production data. A vendor installed remote access on an engineering workstation that talks to the DCS. A dual-homed PC bridges both networks so a report would run. Then a phished user in purchasing gives an attacker a foothold, and those undocumented paths let it move toward the control layer. Even when it stops short, ransomware on the business side can halt shipping and lab release.

  • Undocumented historian and reporting links
  • Dual-homed PCs bridging IT and control networks
  • Vendor remote tools on engineering stations

03 · What we change

Find every crossing, then control it

We map every connection between business and control networks with your controls engineers, then consolidate them into a defined boundary: a DMZ for the historian replica, a jump host with MFA for remote engineering, and firewall rules that allow only what’s needed. Dual-homed machines get retired. Vendor access goes through recorded, time-limited sessions. On the IT side we add endpoint detection, immutable backups for LIMS, ERP and document systems, and tested restores. DCS changes stay with your controls team and vendor.

  • A DMZ and jump host at the IT/OT boundary
  • Recorded, time-limited vendor sessions
  • Immutable backups for LIMS and PSM records

04 · The after

Audits and insurers get straight answers

Your operations manager can point to a diagram that shows exactly how the business network reaches the control layer, and why nothing else does. Lab release keeps moving even if an office workstation is infected. PSM auditors find current documents with change history. Your insurer’s questionnaire about segmentation, remote access and backups gets answered with evidence. And your controls engineers stop being dragged into email and printer problems.

  • A documented IT/OT boundary you can show
  • Lab release unaffected by office incidents
  • Insurance answers backed by real evidence

Systems we keep running

  • SAP S/4HANA
  • LabWare LIMS
  • Thermo Fisher SampleManager LIMS
  • AVEVA PI System
  • Emerson DeltaV
  • Aspen Plus
  • Sphera
  • VelocityEHS

Rules we help you meet

  • OSHA Process Safety Management (29 CFR 1910.119)
  • OSHA Hazard Communication (29 CFR 1910.1200)
  • EPA Risk Management Program (40 CFR Part 68)
  • EAR (Commerce Control List chemicals)
  • MTSA facility security (33 CFR Part 105, waterfront sites)

What We Offer

Comprehensive solutions tailored for Houston-area businesses

IT/OT Boundary Design and Monitoring

With your controls engineers, we document every path between business and control networks and consolidate them into a defined boundary: DMZ, jump host with MFA, and narrow firewall rules. We monitor that boundary for unexpected traffic. We don’t reconfigure the DCS or safety systems; changes inside the control layer stay with your team and the DCS vendor.

LIMS and Quality System Support

LIMS results drive batch release and certificates of analysis, so downtime stops shipments. We keep LIMS servers, databases and instrument-connected PCs patched, monitored and backed up, with access controls and audit logging configured to support your quality system. Restores are tested so a failed server doesn’t mean re-entering weeks of results.

Formulation and Recipe Protection

Formulations, process recipes and customer-specific specs are core intellectual property. We restrict them to the people who need them, log access, and add data loss prevention to flag copying to personal cloud storage or outside email. Departing employees go through an offboarding review of recent file activity before their access is removed.

PSM and EHS Document Availability

Process safety information, management-of-change records, operating procedures and SDS libraries have to be current and reachable. We host them on reliable, backed-up systems with version history and access controls, and set up offline or secondary access so operators can still reach SDS information during an outage on the business network.

Vendor and Remote Engineering Access

DCS vendors, analyzer techs and integrators need remote access at times. We replace always-on tools with a gateway that requires MFA, approval for each session, time limits and recording. You can see who connected, when and what they touched, and switch access off immediately if something looks wrong.

Ransomware Defense for the Business Side

Endpoint detection with 24/7 SOC monitoring, email filtering, MFA, privileged access controls and immutable backups protect ERP, LIMS, shipping and document systems. If an office machine is compromised, it gets isolated quickly, and the boundary design keeps the incident from turning into a control-room problem.

Why Choose LayerLogix?

Serving businesses throughout the Greater Houston area including Houston, Dallas, Austin, San Antonio, Atlanta, Nationwide.

A Boundary You Can Defend

Every connection between business and control networks is documented, justified and monitored. That’s what your insurer, your corporate risk team and any auditor will ask to see, and it gives your controls engineers confidence the office won’t become their problem.

Batches Keep Releasing

Protected, backed-up LIMS and ERP systems mean an IT incident doesn’t leave finished product sitting in tanks waiting on results or a certificate of analysis. Customers keep getting their shipments and paperwork on time. Your lab staff stop re-entering lost results.

Audit-Ready Safety Records

PSM documentation, MOC history and SDS libraries live on systems with version control and backups. Auditors find what they ask for, and operators can reach safety information when the business network is having a bad day.

Formulations Stay Yours

Access restrictions, logging and data loss prevention make it far harder for an attacker or departing employee to take your formulations, and far more likely you’ll catch the attempt before the data ends up somewhere it shouldn’t.

Our Process

1
Inventory business systems, lab instruments, engineering workstations and every known link to the control network, working alongside your controls engineers.
2
Trace undocumented connections such as dual-homed PCs, historian links and vendor tools, and agree on which ones have a real business purpose.
3
Design the IT/OT boundary with a DMZ, jump host and firewall rules, then schedule cutover with operations during a planned window.
4
Harden the business network with MFA, endpoint detection, email filtering and privileged access controls, starting with LIMS and engineering users.
5
Set up immutable backups for LIMS, ERP and PSM document systems, test restores, and build secondary access to SDS information.
6
Review boundary traffic, alerts, vendor sessions and open items with operations and EHS every quarter, updating diagrams as the plant changes.

Frequently Asked Questions

Do you work on our DCS or safety instrumented system?▼
No. The DCS, safety instrumented system and controllers belong to your controls engineers and the vendors who support them, and changes there carry process safety implications. Our work stops at the boundary. We document and secure the connections between the business network and the control layer, set up the DMZ and jump host, monitor boundary traffic, control vendor remote access and protect the business systems around the plant. When a change affects the control side, we plan it with your controls team and let them make it.
Why is the historian connection such a concern?▼
Because it’s often the one sanctioned bridge between control and business networks, and it tends to grow over time. A historian that the business side can query directly, or one that also accepts connections from office PCs, becomes a path an attacker can use. The safer pattern is to replicate historian data to a server in a DMZ that business users query, with the control-side historian sending data outward only. We design that with your controls team and the historian vendor so production reporting keeps working.
How do you keep SDS information available during an outage?▼
OSHA’s Hazard Communication standard expects employees to be able to reach safety data sheets during their shift, and electronic access is fine only if it’s reliable. We host your SDS library on a backed-up system, and we also set up secondary access, such as a synced local copy on a dedicated device in the control room or a printed binder refreshed on a schedule. That way a ransomware event or internet outage doesn’t leave operators without hazard information when they need it.
Can you help with our insurer’s cybersecurity questionnaire?▼
Yes. Underwriters for manufacturers commonly ask about MFA, endpoint detection, backups, privileged access, network segmentation and remote access to control systems. We help you answer accurately and gather the evidence behind each answer, such as MFA reports, backup test logs and a boundary diagram. Where there are gaps, we prioritize the fixes that matter most to the underwriter. We won’t promise a premium change, since that’s the insurer’s decision, but accurate answers with evidence make renewals less painful.
We export some products. Does that affect our IT?▼
It can. Certain chemicals and related technology are listed on the Commerce Control List under the EAR, and technical data about them may need restricted access, including limits on who can see it. If your export compliance lead identifies controlled technology, we help restrict where those files are stored, tie access to authorization and log it. Classification and licensing decisions belong with your compliance team and counsel; we make sure the systems enforce what they decide.
What happens if ransomware hits the business network?▼
Endpoint detection and 24/7 SOC monitoring aim to catch it early and isolate infected machines automatically. Our engineers respond during business hours, and after hours for active incidents. Because the IT/OT boundary is narrow and monitored, the incident should stay on the business side, and your operations team can decide whether to run the process in a more isolated mode. We restore LIMS, ERP and document systems from immutable backups. Regulatory reporting and notification decisions stay with your leadership and counsel.
Do you provide Chemical Manufacturing IT Services in Houston and nearby areas?▼
Yes. LayerLogix is based in the Greater Houston area and delivers chemical manufacturing IT services to businesses across Houston and the surrounding communities, including The Woodlands, Spring, Katy, Sugar Land, Conroe, Cypress, and Pearland. For most Houston-area clients we can be on-site the same day when something needs hands-on attention, and our help desk is available during business hours, with after-hours emergency support. Call 713-571-2390 to check coverage for your specific address.
What does Chemical Manufacturing IT Services cost for a Houston business?▼
Pricing depends on your size and what you need, so we do not publish a one-size-fits-all number — but Houston businesses generally pay a flat, predictable monthly fee rather than surprise hourly bills. We start with a free, no-obligation assessment of your current setup, then give you a clear quote in plain English with no hidden costs. That way you know exactly what you are getting and what it costs before you commit.

Ready to Get Started?

Contact LayerLogix today for a free consultation. We serve businesses throughout Houston, Dallas, Austin, and the surrounding Greater Houston area.

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