The Hidden Costs of Legacy IoT Systems: A Cost-Benefit Analysis

Developers of
the Seemingly
Impossible

Is your Legacy IoT Infrastructure costing more than you think?

Leading an IoT initiative comes with a familiar challenge. Your legacy infrastructure struggles to keep pace with modern IoT demands while market pressures push for rapid digital transformation. Time isn’t on your side, and competitors already implement AI, machine learning, and edge computing solutions. Meanwhile, your team’s expertise in these emerging technologies is limited, and building these capabilities in-house would take precious months you don’t have.

The challenge intensifies when you consider the budget implications. How do you justify the investment in modernization or external expertise to stakeholders who see only the upfront costs? The reality is that maintaining status quo with legacy systems carries its own hefty price tag, one that grows more expensive with each passing quarter.

The True Cost of Legacy System Maintenance

The global engineering services outsourcing market was valued at $2.04 trillion in 2023 and is projected to expand at a compound annual growth rate (CAGR) of 24.4% from 2023 to 2030 (Grand View Research, 2022), indicating the massive shift away from legacy systems maintenance. This growth reflects the increasing recognition that maintaining outdated systems compounds technical debt in IoT environments. Let’s break down the hidden costs:

  1. Operational Inefficiencies
    • Resource Drain: Legacy systems require specialized knowledge of outdated technologies, forcing you to maintain expensive support staff or pay premium rates for rare expertise
    • Decreased Productivity: Older systems often lack automation capabilities, requiring manual intervention for routine tasks that modern systems handle automatically
    • Integration Challenges: Legacy systems struggle to communicate with newer technologies, creating data silos that limit your IoT ecosystem’s potential
  2. Security Vulnerabilities
    • Increased Risk: Outdated systems often lack modern security features, making them prime targets for cyber attacks
    • Compliance Issues: As regulatory requirements evolve, legacy systems may fall short of new security standards, potentially leading to costly fines
    • Limited Patch Support: Vendors eventually discontinue security updates for older systems, leaving your infrastructure exposed
      Learn more on Mastering IoT Security Q&A on Overcoming Engineering Challenges
  3. Scalability Limitations
    • Performance Bottlenecks: Legacy systems often hit performance ceilings that prevent expansion
    • Integration Costs: Adding new capabilities requires expensive custom development and middleware solutions
    • Data Management Issues: Older systems struggle with the volume and velocity of modern IoT data requirements

The Investment Case for Modernization

The engineering services outsourcing market continues to show strong growth (Grand View Research, 2022), reflecting an increasing recognition that modernization is crucial for maintaining competitiveness. Here’s what strategic modernization offers:

  1. Immediate Benefits
    • Reduced Maintenance Costs: Modern systems require up to 75% less maintenance effort
    • Enhanced Security: Built-in security features and regular updates protect your IoT infrastructure
    • Improved Performance: Modern architectures handle IoT workloads more efficiently, reducing operational costs
  2. Long-term Advantages
    • Future-Proof Infrastructure: Scalable architecture that grows with your needs
    • Competitive Edge: Ability to rapidly implement new features and capabilities
    • Talent Attraction: Modern technology stacks help attract and retain top engineering talent

Cost Factors to Consider

When evaluating the financial impact of system modernization, consider these key cost areas:


Legacy System Cost Factors

  • Ongoing maintenance of aging infrastructure
  • Security patches and emergency updates
  • Custom integration work for new capabilities
  • System downtime and reliability issues
  • Specialized staff training and retention
  • Technical debt accumulation
  • Compliance and security risk exposure


Modernized System Benefits

  • Reduced ongoing maintenance needs
  • Automated security updates and patch management
  • Built-in integration capabilities
  • Improved system reliability and uptime
  • Simplified staff training with modern tools
  • Future-proof scalability
  • Enhanced security and compliance features

The exact cost comparison will vary based on your current infrastructure, scale of operations, and specific requirements. Each modernization project is unique, with ROI timelines depending on factors such as:

  • The complexity of existing systems
  • The scope of modernization needed
  • Your organization’s specific efficiency goals
  • Current maintenance and operational costs

We can help you develop a detailed ROI analysis based on your specific situation and modernization objectives.

The Orthogone Advantage

At Orthogone, we understand the complexities of IoT system modernization. Our comprehensive approach across seven key pillars ensures a smooth transition:

  1. Embedded Hardware Platform Design: Custom solutions that maximize performance while minimizing costs
  2. Advanced Embedded Computer Systems: Modern architectures that support current and future IoT needs
  3. Transformational Edge Computing & AI: Intelligent processing that reduces data transmission costs
  4. Comprehensive Wireless Connectivity: Efficient communication protocols that optimize bandwidth usage
  5. Cloud-Native Software Applications: Scalable solutions that grow with your business
  6. IoT Security: Built-in security features that protect your investment
  7. Rigorous Project Management: Careful planning that ensures on-time, on-budget delivery

Making the Decision

While maintaining legacy systems might seem like a safe choice, the numbers tell a different story. Modern IoT infrastructure not only reduces costs but also positions your organization for future growth and innovation.

Consider these questions:

  • How much is your legacy system really costing in terms of maintenance and lost opportunities?
  • What security risks are you accepting by delaying modernization?
  • How will your current infrastructure handle increasing IoT demands?

Take the Next Step

As mentioned above, multiple challenges exist at each stage of software solution development. At Orthogone, we have assembled a team with the expertise that can help you explore IoT security solutions. If you don’t have the expertise or are looking to expand your staff, schedule a call with one of our IoT expert.

Secure, Scalable, Smarter IoT Development with Orthogone. We cover the entire spectrum—hardware design, embedded software development, and seamless cloud integration.

Olivier Allaire
Technical and Customer Account Manager

Our culture of innovation is rooted in the spirit of collaboration, communication and our love of new challenges.