If you have a lot of traffic/requests, this load can build up without any obvious notice. In my experience if it is over 25-40% CPU, you are probably gaining latency and possibly losing packets just because of the load. My suspicion is the network stack is not very good. And it does so far more quickly than you might thing. When you start losing packets, the whole thing degrades really badly. When the network is healthy with zero packet loss, everything is great. A lot of industrial networks are held together with spit and baling wire and it shows when you look at packet loss and retransmission counts.
The network itself can be a big factor.If you have any ENBTs, just throw them away and get a better network module.
If you are talking to a PLC/5, you can go get a cup of coffee while you wait for the packets to come back. If that is not possible, an EN2T is better than an ENBT. If the rest of your network can keep up, this will make a huge difference. An L81 CPU with a gigabit controller will smash anything else with very low latency and high throughput.
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