IMO, the only way to have a reasonably secure device is to build it yourself. That's not going to be a popular opinion where the prevailing motto is "nobody gets fired for buying Cisco", but I don't really see any alternative. OpenWRT/Tomato are decent, but they still expose a web UI which is potentially a greater attack surface than ssh w/ public keys.
I've seen some people have good results with OpenBSD or FreeBSD, others with skinny versions of Debian or CentOS. I took a crack at it last year on Debian (shameless plug: https://nbailey.ca/post/linux-firewall-ids/), and I've been happy with it so far. It is more expensive to build, but I expect this device to last more than a decade, or until I need greater than 1gbps per port.