Top 10 Advancements in Honeywell DCS Systems Expected by 2026

Increased industrial autonomy, AI integration, cloud connectivity, sustainability, and energy management are some common developments expected from Honeywell DCS systems in 2026.

Honeywell DCS (Distributed Control Systems), like the Experion PKS platform, is designed to provide integrated automation for complex industries. It offers centralized control, enhances reliability, and improves industrial productivity, working seamlessly with field devices and process pipelines. 

To build efficient, secure, and sustainable systems, the Honeywell DCS systems and similar devices are poised for certain advancements by 2026.

10 Advancements Expected in Honeywell DCS Systems

By 2026, Honeywell is expected to bring forth the following advancements in Honeywell control systems, like DCS systems and PLC modules.

1. Honeywell Cyber Proactive Defense

An AI-powered cybersecurity solution, the Honeywell Cyber Proactive Defense is designed to work with the Honeywell programmable logic controller and distributed control system to enhance cybersecurity for industrial environments.

This proactively identifies and mitigates potential cyber threats before they turn into cyberattacks. This platform uses AI and behavior-based analytics to detect anomalies in OT cyber behavior. It establishes a comprehensive baseline by analyzing system operations and then provides the engineer and operators with actionable insights on how to strengthen cyber defenses. 

Further, the software is also designed to feature deception technology, using decoys within the network to effectively divert attackers away from valuable assets and critical systems.

2. Honeywell OT Security Operations Center

Also designed with cybersecurity in mind, the Honeywell OT Security Operations Center is a vendor-agnostic and agentless service. This is designed to equip all industries with advanced capabilities tailored to OT environments and monitor for the signs of a potential cyberattack. 

Further, it integrates with on-site incident management services and offers a 24/7/365 holistic view of the potential cyber threats posed to Honeywell’s distributed control systems and programmable logic controllers.

This makes it a great addition, offering security and resilience to Honeywell DCS automation.

3. Honeywell Digital Prime Ecosystem

The Honeywell Digital Prime Ecosystem features three offerings in a single platform:

• Solution Enhancement Support Program (SESP)
• Enabled Services
• Assurance 360

The consolidation of the three into a single platform allows users to leverage deep domain knowledge and use it to optimize the Honeywell distributed control systems. The result is better, timely maintenance, and operational effectiveness across the industrial infrastructure of an organization.

The Honeywell Digital Prime Ecosystem is also designed to offer near real-time performance insights for all connected industrial machinery. This helps users achieve the targeted outcome from their industrial pipeline faster, while depending less on the technical expertise of an experienced workforce.

4. Lean Project Execution (LEAP™) Methodology Enhancements

Compatible with the Honeywell Experion PKS, LEAP™ is designed to revolutionize automation project execution. Thus, it enhances project execution through Universal IO Cabinets, virtualization, cloud engineering, and auto-device commissioning. 

Thus, it effectively separates physical setup from functional design through virtualization, making room for standardized workflows and engineering. It can also reduce hardware requirements and ensure fault tolerance in mission-critical applications. 

Using LEAP™ can dramatically reduce/eliminate traditional marshalling cabinets, reducing hardware requirements, footprint, and wiring mistakes. Through refinement of the LEAP™ methodology, engineers can effectively minimize risk, shorten project schedules, and avoid overruns during system implementation and upgrades.

5. Experion PKS HIVE Integration

The next-gen industrial control system architecture, the Honeywell Experion PKS HIVE (Highly Integrated Virtual Environment), decouples physical hardware from physical hardware (IT, IO, Controllers), enabling the following:

• Greater flexibility without complex recommissioning 
• Faster project execution and delivery
• Robust disaster recovery through virtualization
• Lower project costs and lifecycle expenses

The Honeywell Experion PKS HIVE allows engineers to integrate multiple controllers into a shared cluster, which acts as a control data center with universal I/O access. Thus, it allows engineers to skip complex rewiring by adding a cabinet to the IO HIVE and a controller to the Control HIVE. Additionally, it virtualizes the control system, turning the rigid hardware dependencies into software-defined assets.

6. Advanced Cloud and Edge Computing Capabilities

Through Honeywell Forge, a hardware-agnostic, open-architecture IoT platform, engineers can leverage cloud technology to manage vast amounts of data and deliver efficient enterprise-wide solutions. The Honeywell Forge platform allows unified visualization of data aggregated from multiple locations for trend analysis and better decision-making. It also offers predictive analytics, remote monitoring, and proactive solutions to sustain maximum yield and performance.

In edge devices, such as the Honeywell ControlEdge PLC modules, local data processing offers fast response times, which is critical to operations. These also perform self-diagnosis, automate maintenance alerts, and execute control logic autonomously, effectively reducing manual intervention and dependence on the centralized Honeywell programmable logic controller.

7. Improved Operator Consoles (Experion Orion Console)

The Experion^® Orion Console by Honeywell is designed to increase operator effectiveness with faster response, less fatigue, and increased situational awareness. Featuring ultra-high-definition screens and an ergonomic design, this bundled solution by Honeywell provides out-of-the-box console furniture that is integrated with control system software. 

Using the Experion^® Orion Console, operators can achieve faster product/production transitions. They can also respond quickly to any deviations, threats, and abnormal situations. It also improves cable management, effectively reducing installation and maintenance costs.

8. Seamless Integration with Smart Field Instruments

The Honeywell Experion PKS and Field Device Manager (FDM) use open communication protocols (HART, FOUNDATION Fieldbus, Modbus, Profibus, and Profinet) and specialized software platforms to connect to field devices. The Honeywell Experion PKS Distributed Control Systems (DCS) offers “out-of-the-box” integration with SmartLine devices, allowing extended diagnostics, real-time data monitoring, and simplified maintenance.

This leads to reduced project engineering time, preventing startup delays, and reducing overall downtime. These also enable predictive failure monitoring, optimizing maintenance schedules, and improving plant efficiency. Further, this can potentially improve safety and operational effectiveness through remote configuration, maintenance, and real-time data monitoring.

9. Sustainability and Energy Transition Support

Honeywell is committed to making energy transition work for industries. Thus, Honeywell PLC modules and DCS systems are designed to help industries transition to using automation digitalization that manages carbon impact. Further, they are dedicated to making their operations carbon neutral by 2035. 

To date, Honeywell has achieved the following:

• 90% reduction in greenhouse gas intensity.
• 70% greater energy efficiency.
• More than 60% of R&D investment in sustainability-oriented outcomes.

Now, Honeywell works on developing industrial machinery and solutions, including DCS and PLC modules, designed to perform efficiently and stay relevant for the next 100+ years.

10. Focus on Industrial Autonomy

With Industry 4.0 and associated industrial autonomy being the greatest demand, Honeywell is integrating AI into its digital solutions. Thus, their products go beyond basic automation components to intelligent devices that drive safety, efficiency, and productivity.

This includes:

• AI-enabled digital suite for process optimization and predictive maintenance.
• AI-powered cybersecurity solutions for resilient critical industrial networks.
• Digital Prime platform to create a digital twin for testing and simulation.
• Edge-to-Cloud (E2C) framework for remote and autonomous control.

Further, it is expected that Honeywell will lead the way in AI-enabled autonomous industrial operations that can address labor shortages, industrial safety, sustainability, digital transformation, and boost productivity.

Wrapping Up

From better cybersecurity to sustainability, Honeywell has a lot to offer in 2026. Further, they offer a broad range of solutions that can support the unique needs of every industry. Their emphasis on providing sustainable and efficient industrial solutions has made them a brand to watch out for.

Effective and Efficient Automation with Honeywell

Ready to future-proof your industrial process? Opt for Honeywell DCS systems and similar devices for your process industry.

Frequently Asked Questions

Can I upgrade to Honeywell Experion PKS from TDC 3000?

Honeywell offers structured migration paths like Experion Local Control Network (ELCN) to support upgrades from legacy systems. This facilitates an incremental upgrade that preserves your existing control logic and IP, allowing you to integrate new Experion features while keeping valuable legacy controllers.

Do Honeywell DCS Systems Offer Redundancy?

Redundancy is a key feature of Honeywell DCS systems. Further, hardware redundancy is available for controllers, I/O modules, power supplies, and communication networks (like FTE) to ensure system availability, reliability, and fault tolerance in case of hardware failures.

Can Third-party Systems and Devices Be Integrated With Honeywell Dcs Systems and PLC Modules?

Modern Honeywell DCS systems use open architecture and support industry-standard protocols, like HART, Foundation Fieldbus, and Profibus. This allows integration with smart field instruments and third-party systems, reducing engineering effort and the cost of upgrading third-party field devices to those offered by Honeywell.

How Secure Are Current Honeywell DCS Systems From Cyber Threats?

System security for Honeywell DCS is ensured through robust cybersecurity infrastructure, secure network integration with firewalls, and remote access with secure VPNs. These mitigate the risk of cyber threats. Further, the Honeywell Cyber Proactive Defense and the Honeywell OT Security Operations Center are being launched to improve cybersecurity.