A multi-site network strategy for NC manufacturing companies connects multiple facilities, including main offices, production floors, warehouses, and satellite locations, through a unified network architecture that provides consistent connectivity, centralized management, and secure communication between all sites while supporting both office IT and operational technology (OT) requirements.
Key takeaway: According to Fortinet's SD-WAN comparison guide, SD-WAN reduces expenses by utilizing cost-effective broadband internet while providing application-aware routing, built-in encryption, and simplified management. The cost of SD-WAN typically ranges from $100-$300 per site per month versus $300-$1,000+ per site per month for MPLS, according to Zscaler's analysis. For multi-site NC manufacturers, the hybrid approach of SD-WAN plus MPLS for critical applications delivers the best balance of cost and performance.
For manufacturing companies across North Carolina growing from one facility to two, three, or more locations in the Piedmont Triad, Charlotte, and surrounding areas, a well-designed multi-site network eliminates the connectivity gaps and security risks that plague ad-hoc expansion. The common NC scenario of a main manufacturing plant in High Point or Greensboro plus a warehouse in a nearby city plus a satellite office in Charlotte or Raleigh demands intentional network architecture.
Planning a multi-site network for your NC manufacturing company? Preferred Data Corporation designs and manages network infrastructure for multi-location North Carolina manufacturers. With 37+ years of expertise and BBB A+ accreditation, we connect your facilities securely. Call (336) 886-3282 or schedule a network assessment.
Site-to-Site Connectivity Options
Option 1: MPLS (Multiprotocol Label Switching)
MPLS provides dedicated, private circuits between locations with guaranteed performance characteristics.
How it works: Your ISP creates private labeled paths through their network, providing predictable latency, guaranteed bandwidth, and built-in quality of service (QoS).
Advantages:
- Guaranteed performance and low latency
- Built-in QoS for voice and critical applications
- High reliability with carrier SLAs
- Private network (not traversing public internet)
- Ideal for real-time OT applications
Disadvantages:
- Expensive ($300-$1,000+ per site per month for 50-100 Mbps)
- Long provisioning times (30-90 days for new circuits)
- Limited bandwidth for the cost
- Poor cloud application performance (requires backhauling)
- Inflexible for adding new locations quickly
Best for NC manufacturers: Sites running real-time production control or SCADA systems where latency spikes are unacceptable, or locations with limited broadband options.
Option 2: SD-WAN (Software-Defined Wide Area Network)
SD-WAN overlays intelligent routing and encryption on top of standard broadband connections.
How it works: SD-WAN appliances at each site create encrypted tunnels over multiple internet connections, dynamically routing traffic based on application requirements and real-time link performance.
Advantages:
- Cost-effective ($100-$300 per site per month for edge device plus broadband)
- Rapid deployment (days to weeks, not months)
- Application-aware routing (voice traffic prioritized automatically)
- Direct cloud access (no backhauling to main site)
- Dual ISP failover for high availability
- Centralized management of all sites from single console
Disadvantages:
- Performance depends on underlying ISP quality
- Cannot guarantee latency for the most demanding OT applications
- Requires reliable broadband at each location
- May add complexity if combined with MPLS
Best for NC manufacturers: Most site-to-site connectivity needs, especially cloud-connected facilities, remote offices, and locations where broadband is readily available.
According to Lightyear's SD-WAN cost guide, at 2 Gbps, SD-WAN pricing variation ranges from $496 to $1,256 monthly depending on provider and features, with most organizations seeing savings within the first year when migrating from MPLS.
Option 3: Site-to-Site VPN over Broadband
The simplest approach: encrypted tunnels between firewall appliances at each location over standard internet connections.
How it works: IPsec VPN tunnels between firewalls create encrypted paths between sites. Traffic is encrypted at the source firewall and decrypted at the destination.
Advantages:
- Lowest cost (firewall to firewall, no additional service fees)
- Simple to implement with modern firewalls
- Adequate for most office-to-office communication
- No dependency on WAN service provider
Disadvantages:
- No intelligent routing (all traffic takes the same path)
- No automatic failover without SD-WAN features
- Performance limited by weakest ISP connection
- No centralized traffic management
- QoS limited to local network segments
Best for NC manufacturers: Connecting 2-3 sites with basic office connectivity needs and limited inter-site traffic volume.
Option 4: Hybrid Approach (Recommended)
According to TechTarget's analysis, organizations considering SD-WAN often intend to retain MPLS in their architectures, overlaying SD-WAN and internet services onto existing MPLS WANs.
Recommended hybrid for NC manufacturers:
- MPLS: Critical OT traffic between production facilities (SCADA, real-time control)
- SD-WAN: All office traffic, cloud applications, video, voice, and general data
- VPN: Backup connectivity and temporary connections
This approach lets cloud-bound traffic bypass MPLS using local internet breakout, keeping such packets off MPLS links and enabling existing MPLS bandwidth to serve mission-critical OT traffic for years longer.
Centralized vs. Distributed Services
Centralized Architecture
All servers, applications, and data reside at the main facility. Branch sites access everything over WAN connections.
Advantages: Easier backup, single security boundary, simpler management Disadvantages: WAN dependency for all work, single point of failure, latency for remote users
Appropriate when: Inter-site bandwidth is high and reliable, branch sites have few users, and most work is cloud-based.
Distributed Architecture
Each site has local servers for critical functions (file sharing, authentication, print services) with replication to the main site.
Advantages: Continues operating during WAN outages, lower latency for local access, reduced WAN bandwidth requirements Disadvantages: More complex management, more servers to maintain, replication complexity
Appropriate when: Branch sites have many users, WAN reliability is uncertain, or production cannot tolerate WAN-dependent systems.
Hybrid Architecture (Most Common for NC Manufacturers)
- Centralized: ERP, financial systems, email/collaboration (Microsoft 365)
- Distributed: Local file caching, Active Directory domain controllers, DHCP/DNS, print services
- Site-specific: OT/SCADA systems at each production facility
Active Directory Design for Multi-Site
Proper AD architecture ensures authentication, group policy, and access management work across all NC locations.
Single Domain, Multiple Sites
Recommended for most NC manufacturers:
- One Active Directory domain (e.g., yourcompany.local)
- AD Sites defined for each physical location
- Domain controller at each site with 25+ users
- Site links configured for replication timing
- DNS integrated with AD at each site
Benefits:
- Users authenticate locally even during WAN outages
- Group Policy applies consistently across all sites
- Single user management across the organization
- Proper replication ensures consistency
DNS and DHCP Design
DNS:
- AD-integrated DNS at each site (on domain controllers)
- Forwarders to external DNS (Cloudflare, Google, ISP)
- Split DNS for internal vs. external resolution
- Proper reverse lookup zones for each subnet
DHCP:
- Local DHCP server or relay at each site
- Centralized DHCP if WAN is highly reliable
- Separate scopes for each site and VLAN
- Reservations for critical devices (printers, servers, OT equipment)
Unified Network Management
Managing multiple sites requires centralized visibility and control. For NC manufacturers with facilities in High Point, a warehouse in Kernersville, and offices in Charlotte, managing each site independently creates gaps and inconsistencies.
Management Platform Options
- FortiManager (Fortinet): Centralized management for all FortiGate firewalls and SD-WAN
- Meraki Dashboard (Cisco): Cloud-managed switches, APs, firewalls across all sites
- SonicWall NSM: Network Security Manager for multi-site SonicWall environments
- Auvik: Cloud-based network monitoring and management across distributed sites
Key Management Requirements
- Single dashboard showing all site status and health
- Centralized configuration management (change once, deploy everywhere)
- Unified alerting and escalation across all locations
- Consistent security policies applied organization-wide
- Bandwidth and utilization reporting per site
- Configuration backup and change tracking
Implementation Roadmap for NC Multi-Site Manufacturers
Phase 1: Assessment and Design (Weeks 1-4)
- Audit current connectivity at all sites
- Document applications and traffic flows between sites
- Define bandwidth requirements per application and site
- Assess ISP options at each location
- Design target architecture (hybrid SD-WAN + MPLS if applicable)
- Develop security policy for inter-site communication
Phase 2: Core Infrastructure (Weeks 5-8)
- Deploy or upgrade firewalls at each site
- Establish site-to-site connectivity (SD-WAN, VPN, or MPLS)
- Configure AD Sites and deploy domain controllers
- Set up DNS/DHCP at each location
- Implement network segmentation (IT, OT, guest, voice)
Phase 3: Application Migration (Weeks 9-12)
- Migrate applications to centralized or distributed architecture
- Configure cloud application direct internet access via SD-WAN
- Implement backup and replication across sites
- Deploy unified monitoring and management platform
- Configure QoS policies for voice and critical applications
Phase 4: Optimization (Weeks 13-16)
- Tune SD-WAN application routing policies
- Optimize bandwidth allocation based on actual usage
- Implement failover testing and document procedures
- Train IT staff on multi-site management tools
- Establish ongoing monitoring and reporting cadence
Ready to connect your NC manufacturing locations? Preferred Data Corporation designs multi-site networks for North Carolina manufacturers with facilities across the Piedmont Triad, Charlotte, and beyond. Call (336) 886-3282 or start your network design.
Cost Comparison for NC Multi-Site Manufacturers
3-site scenario: Main plant (Greensboro) + Warehouse (Kernersville) + Office (Charlotte)
| Component | MPLS Only | SD-WAN Only | Hybrid |
|---|---|---|---|
| Monthly WAN cost | $2,500-$4,000 | $600-$1,200 | $1,500-$2,500 |
| Firewall hardware | $3,000-$8,000 | $5,000-$12,000 | $5,000-$12,000 |
| Implementation | $5,000-$15,000 | $8,000-$20,000 | $10,000-$25,000 |
| Annual management | $3,000-$8,000 | $4,000-$10,000 | $5,000-$12,000 |
| 3-year total | $120,000-$200,000 | $50,000-$100,000 | $80,000-$145,000 |
Common Multi-Site Mistakes
- [ ] Adding sites without updating the overall network architecture
- [ ] Using different firewall vendors at different locations (complicates management)
- [ ] Not deploying local AD domain controllers at sites with 25+ users
- [ ] Routing all traffic through the main site (creating bottlenecks for cloud apps)
- [ ] Ignoring OT network requirements at production facilities
- [ ] Not testing failover scenarios (what happens when the WAN goes down?)
- [ ] Treating each site as independent rather than part of unified architecture
Frequently Asked Questions
When should a NC manufacturer switch from VPN to SD-WAN?
Consider SD-WAN when you have three or more sites, when cloud application performance over VPN is poor due to backhauling, when you need automatic failover between ISP connections, or when WAN management complexity is consuming too much IT time. For most Piedmont Triad manufacturers growing beyond two locations, SD-WAN provides better performance at lower cost than site-to-site VPN with separate ISP failover configurations.
Can I keep MPLS for my production network and use SD-WAN for everything else?
Yes, and this hybrid approach is recommended for NC manufacturers with real-time OT requirements. Keep MPLS for SCADA, PLC communications, and other latency-sensitive production traffic between facilities. Use SD-WAN for office applications, email, cloud services, video conferencing, and general data transfer. This maximizes the value of both technologies while managing costs.
How do I handle network segmentation across multiple sites?
Maintain consistent VLAN and subnet design across all sites. Common approach: use the same VLAN IDs at each site but different subnets (e.g., VLAN 10 = production: 10.1.10.0/24 at Site 1, 10.2.10.0/24 at Site 2). Implement firewall rules between VLANs that apply consistently across sites. OT and IT networks should be segmented at every location, not just the main facility.
What happens to branch sites when the WAN connection fails?
With proper distributed architecture, branch sites continue operating for critical local functions: local file access, authentication (local domain controller), printing, and OT systems. Cloud-dependent applications (email, ERP if cloud-hosted) will be unavailable during the outage. SD-WAN with dual ISP connections at each site significantly reduces outage risk through automatic failover.
Should I use the same ISP at all locations for simplicity?
Using the same ISP simplifies billing and support relationships but creates a single-provider risk. For critical sites, use dual ISPs from different providers for true redundancy. In the Piedmont Triad area, options typically include AT&T, Spectrum, and local fiber providers. For SD-WAN deployments, provider diversity at each site maximizes failover effectiveness.
Connect Your Facilities with PDC
Preferred Data Corporation has served North Carolina manufacturers for over 37 years from our High Point headquarters. Our BBB A+ rated team designs and manages multi-site networks for manufacturers across the Piedmont Triad, Charlotte, and Research Triangle.
Our multi-site network services include:
- Network architecture design for distributed manufacturing
- SD-WAN deployment and management
- Network infrastructure at each location
- Active Directory and DNS/DHCP design
- OT/IT network segmentation across all sites
- Managed IT services for all locations from one provider
- Cybersecurity policies applied consistently across sites
- On-site support within 200 miles of High Point
Connect your manufacturing locations today. Call Preferred Data Corporation at (336) 886-3282 or request a multi-site network assessment. We will design a unified network strategy that connects your North Carolina facilities reliably, securely, and cost-effectively.