Pellion Manufacturing connected 62 plants without a production stop.

Pellion's plants ran on a network built over twenty years, with operational technology flat against corporate traffic — a configuration that was both a reliability risk and an audit finding.

Vertane designed a segmented SD-WAN topology sized against measured traffic rather than vendor reference designs, then rolled it out one plant at a time inside scheduled maintenance windows. Every cutover had a tested rollback, and the OT segmentation was validated with the plant engineering team before the window closed.

Sixty-two plants were migrated with no unplanned production downtime, and WAN cost fell 38% against the previous circuit inventory.