Should I just replace Modbus with something secure?
Rarely practical, and not the first move. Modbus is embedded in decades of installed devices, and even brand-new equipment ships with it because integrators expect it. The realistic posture is to treat Modbus as untrusted by design and build the controls around it — segmentation, filtering, monitoring — while preferring secure protocols where genuine replacement opportunities arise.
What about Modbus/TCP Security — the TLS version?
Modbus.org published a TLS-wrapped variant (port 802) with certificate-based, role-based access control in 2018. It solves the protocol's problems on paper, but device support remains rare — almost no installed base speaks it. Worth specifying when procuring new equipment; not something to plan a brownfield remediation around today.
Is serial Modbus (RTU) safe since it's not on the network?
Safer from remote attack, but not immune: serial lines are usually bridged onto TCP through gateways — which inherit every problem above and add their own (many popular serial-to-Ethernet gateways have shipped with serious vulnerabilities). And anyone with physical access to the RS-485 trunk can inject traffic. Treat gateways as network devices: inventory, patch, and firewall them.
Does putting Modbus inside a VPN fix it?
A VPN protects the transit path — useful across untrusted networks and far better than raw exposure. But it authenticates the tunnel, not the Modbus requests inside it: every host on either end of the tunnel can still issue any command. Combine tunnelling with the function-code and source restrictions above rather than treating it as complete.