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    Industrial Controllers Market

    ID: MRFR/SEM/7172-CR
    128 Pages
    Ankit Gupta
    March 2024

    Industrial Controllers Market Research Report Information By Type (Programmable Logic Controllers (PLC), Distributed Control Systems (DCS), Supervisory Control and Data Acquisition (Scada), and Programmable Automation Controllers (PAC)), By Control (On-Off Control, Open Loop Control, Closed-Loop Control and Feed-Forward Control), By Application (Automotive, Manufacturing, Oil & Gas, Energy & Utilities, Water & Wastewater, Food Processing & Beverage, Aerospace & Aviation, and Others) And By Region (North America, Europe, A...

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    Industrial Controllers Market Summary

    As per Market Research Future Analysis, the Global Industrial Controllers Market was valued at USD 160406.62 million in 2024 and is projected to reach USD 305139.89 million by 2035, growing at a CAGR of 6.02% from 2025 to 2035. Key drivers include rising labor costs and the need for timely production. The integration of AI and ML in PLC-based applications is expected to enhance automation and process optimization, significantly impacting market growth. The Asia-Pacific region accounted for approximately 43% of the market share in 2022, driven by increased demand for operational efficiency and automation technologies in manufacturing.

    Key Market Trends & Highlights

    The Industrial Controllers market is witnessing significant advancements and shifts driven by technology and regional demands.

    • AI and ML integration in PLCs is expected to enhance predictive maintenance and real-time anomaly detection.
    • Distributed Control Systems (DCS) held a ~32% market share in 2022, dominating the Industrial Controllers segment.
    • Open-loop control systems dominated the market in 2022 due to their simplicity and cost-effectiveness.
    • The manufacturing sector accounted for the largest share of the Industrial Controllers market in 2022.

    Market Size & Forecast

    2024 Market Size USD 160406.62 million
    2035 Market Size USD 305139.89 million
    CAGR (2024-2035) 6.02%

    Major Players

    Siemens AG, ABB Ltd., Rockwell Automation, Schneider Electric, Honeywell International

    Industrial Controllers Market Drivers

    Regulatory Compliance

    Regulatory compliance is a crucial factor influencing the Global Industrial Controllers Market Industry. Governments worldwide are implementing stringent regulations to ensure safety, quality, and environmental protection in industrial operations. Compliance with these regulations necessitates the adoption of advanced control systems that can monitor and report on various operational parameters. For instance, industries must adhere to standards set by organizations such as the International Organization for Standardization. This regulatory landscape drives the demand for sophisticated industrial controllers, as companies seek to avoid penalties and enhance their operational integrity.

    Emerging Markets Growth

    The Global Industrial Controllers Market Industry is poised for growth, particularly in emerging markets. Countries in Asia-Pacific and Latin America are witnessing rapid industrialization, leading to increased investments in manufacturing and infrastructure. This growth presents opportunities for industrial controllers, as businesses in these regions seek to modernize their operations. For example, the expansion of manufacturing hubs in India and Brazil is driving demand for advanced control systems. As these markets develop, the Global Industrial Controllers Market is expected to benefit from increased adoption of automation technologies, further propelling its growth trajectory.

    Focus on Energy Efficiency

    Energy efficiency has emerged as a pivotal driver in the Global Industrial Controllers Market Industry. Companies are increasingly prioritizing sustainable practices to reduce operational costs and minimize environmental impact. Advanced industrial controllers enable precise monitoring and control of energy consumption, leading to significant savings. For example, industries that implement energy-efficient control systems can reduce energy usage by up to 30 percent. This focus on sustainability not only aligns with global environmental goals but also enhances the competitiveness of businesses in the market, contributing to a projected CAGR of 6.02% from 2025 to 2035.

    Technological Advancements

    The Global Industrial Controllers Market Industry is experiencing a surge in demand driven by rapid technological advancements. Innovations in automation, artificial intelligence, and the Internet of Things are reshaping industrial processes. For instance, the integration of smart sensors and advanced control algorithms enhances operational efficiency and reduces downtime. This trend is evident as industries increasingly adopt these technologies to optimize production. As a result, the market is projected to reach 160.4 USD Billion in 2024, reflecting a growing reliance on sophisticated control systems to meet the demands of modern manufacturing.

    Rising Demand for Automation

    The Global Industrial Controllers Market Industry is significantly influenced by the rising demand for automation across various sectors. Industries such as manufacturing, oil and gas, and pharmaceuticals are increasingly automating their processes to improve productivity and reduce labor costs. This shift is evident in the growing adoption of programmable logic controllers and distributed control systems. As companies seek to enhance operational efficiency, the market is expected to grow substantially, with projections indicating a value of 305.1 USD Billion by 2035. This trend underscores the critical role of industrial controllers in facilitating seamless automation.

    Market Trends and Projections

    Market Segment Insights

    Industrial Controllers Market Platform Segment Insights:

    Industrial Controllers Type Insights

    Based on Type, the Industrial Controllers Market segmentation includes programmable logic controllers (PLC), distributed control systems (DCS), supervisory control and data acquisition (Scada), and programmable automation controllers (PAC). The distributed control systems (DCS)held the majority share in 2022, contributing around ~32% to the market revenue. DCSs arose to regulate process systems such as oil refineries and water treatment plants. PLCs now perform many of the same functions as DCSs, but DCSs are more tightly connected with the operator display (HMI, Human Machine Interface) and engineering configuration system.

    A DCS is a central monitoring network that connects devices to control various parts of an automated system. A distributed control system (DCS) is a type of digital automated industrial control system (ICS) that employs geographically distributed control loops throughout a factory, machine, or control region. A DCS's purpose is to control industrial processes in order to improve their safety, cost-effectiveness, and dependability. DCSs are made up of control elements that are deployed throughout a plant or facility. Computers, sensors, and controllers are among the control elements.

    Each component has a distinct function, such as data gathering, data storage, or process control.

    Industrial Controllers Control Insights

    Based on the Control, the Industrial Controllers Market segmentation is on-off control, open loop control, closed-loop control and feed-forward control. Open loop control dominated the market in 2022. An open-loop controller, also known as a non-feedback controller, is a form of controller that computes its input into a system using only the system's current state and model. Because of its simplicity and low cost, it is frequently employed in simple processes, particularly in systems where feedback is not crucial.

    The open-loop controller is distinguished by the fact that it does not rely on feedback to determine whether its input has accomplished the desired result. This means that the system does not monitor the output of the processes it manages. As a result, a true open-loop system cannot engage in machine learning or repair any faults that may occur. It may also fail to compensate for system interruptions. The electrical controller, which has an output to an actuator, is one of the components of an open-loop controller.

    In turn, the actuator regulates the plant under control based on the desired relationship between the command input and the value of the controlled variable in the plant..

    Industrial Controllers Application Insights

    Based on end-user, the Industrial Controllers Market segmentation includes automotive, manufacturing, oil & gas, energy & utilities, water & wastewater, food processing & beverage, aerospace & aviation, and others. The manufacturing owners held the majority share in 2022. Industrial controllers are computer-based devices used for production and process control in situations where standard electronics would fail or be destroyed. Industrial control is an essential component of every manufacturing automation process. A simple panel-mounted controller to massive networked and interactive distributed control systems are examples.

    PLCs are essential in industrial control; their principal job is to control individual units or stations in real time, which necessitates low deterministic latency. PLCs may control RF transistors instead of vacuum tubes in industrial power applications, ensuring accurate power control across a wide dynamic range. NFC can be used to replace DIP switches, service UARTs, and other electromechanical elements in PLC programming to make it smarter and more secure.

    Get more detailed insights about Industrial Controllers Market Research Report - Global Forecast till 2032

    Regional Insights

    By Region, the study provides market insights into North America, Europe, Asia-Pacific, and the Rest of the World. The Asia Pacific Industrial Controllers market accounted for ~43% in 2022. It is expected to exhibit a significant CAGR growth during the study period. The demand for industrial controllers in the region is primarily driven by the growing need for operational efficiency, improved production processes, and better quality control. China is one of the largest markets for industrial controllers in the Asia-Pacific region, accounting for a significant share of the market.

    The country has witnessed significant growth in the manufacturing sector, which has led to the adoption of automation technologies in various industries. The industrial control system has emerged in China across a variety of sectors, including energy, transportation, water, and municipal services.

    FIGURE 3: INDUSTRIAL CONTROLLERS MARKET SIZE BY REGION 2022 VS 2032 (USD Million)

    INDUSTRIAL CONTROLLERS MARKET SIZE BY REGION 2022 VS 2032 (USD Million)

    Source: Secondary Research, Primary Research, MRFR Database, and Analyst Review

    Further, the major countries studied in the market report are the U.S., Canada, Germany, France, the UK, Italy, Spain, China, Japan, India, Australia, South Korea, and Brazil.

    North America market accounts for the second-largest market share. The region is home to several leading industrial automation companies, such as Rockwell Automation, Honeywell, Siemens, and ABB, which have a strong presence in the market. The increasing demand for automation in various industries, such as automotive, food and beverage, chemicals, and pharmaceuticals, drives the market. The need for efficient and cost-effective manufacturing processes is driving the adoption of industrial controllers in these industries.

    The Europe Industrial Controllers Market is expected to grow at the fastest CAGR between 2022 and 2032. Various manufacturing industries have been forced to reevaluate their traditional production processes as a result of COVID-19, which primarily drove digital transformation and smart manufacturing practices across production lines. Furthermore, manufacturers must devise and implement multiple new and agile quality control and product monitoring approaches. Internet of Things (IoT) and machine-to-machine (M2M) technologies are becoming increasingly important for reducing manufacturing costs.

    Key Players and Competitive Insights

    With a strong presence across different verticals and geographies, the Industrial Controllers market is highly competitive and dominated by established, pure-play vendors. Over 20 vendors cater to this market, and they continually innovate their solutions to meet the evolving needs of businesses by adopting new technologies. These vendors have a robust geographic footprint and partner ecosystem to cater to diverse customer segments. The Industrial Controllers market is highly competitive, with many vendors offering similar products and services.

    The major players in the market include Siemens AG, ABB Ltd., Rockwell Automation, Schneider Electric, and Honeywell International. Siemens is continuously expanding its product portfolio with significant investments in research and development. The company is focused on enhancing its service offerings and expanding its global presence through mergers & acquisitions to strengthen its expertise in technology.

    The Industrial Controllers Market is consolidated, increasing competition, acquisitions, mergers, and other strategic market developments and decisions to improve operational effectiveness.

    Key Companies in the Industrial Controllers Market market include

    Industry Developments

    • In January 2023, B&R Industrial Automation Gmbh launched the X2X+ backplane bus as an option, increasing the performance of the X20 system by a factor of four. And because all existing X20 I/O modules are already compatible with X2X+, all it takes to build more powerful machines are bus modules.
    • In November 2022, Rockwell Automation enhanced the Allen‑Bradley Micro850 and Micro870 2080-Lx0E controllers using the latest Connected Components Workbench software from Rockwell Automation. The improved 2080-Lx0E controllers offer greater connectivity and design efficiency through the new Class 1 implicit messaging capability with up to eight EtherNet/IP devices support.

    Future Outlook

    Industrial Controllers Market Future Outlook

    The Global Industrial Controllers Market is projected to grow at a 6.02% CAGR from 2025 to 2035, driven by automation, IoT integration, and demand for energy efficiency.

    New opportunities lie in:

    • Develop advanced AI-driven controllers for predictive maintenance. Expand into emerging markets with tailored solutions for local industries. Invest in cybersecurity features to enhance product reliability and safety.

    By 2035, the market is expected to achieve substantial growth, reflecting evolving technological advancements and increased industrial automation.

    Market Segmentation

    Industrial Controllers Type Outlook

    • Programmable Logic Controllers (PLC)
    • Distributed Control Systems (DCS)
    • Supervisory Control and Data Acquisition (Scada)
    • Programmable Automation Controllers (PAC)

    Industrial Controllers Control Outlook

    • On-Off Control
    • Open Loop Control
    • Closed-Loop Control
    • Feed-Forward Control

    Industrial Controllers Regional Outlook

    • {"North America"=>["US"
    • "Canada"]}
    • {"Europe"=>["Germany"
    • "UK"
    • "France"
    • "Italy"
    • "Spain"
    • "Turkey"
    • "Rest of Europe"]}
    • {"Asia-Pacific"=>["China"
    • "Japan"
    • "South Korea"
    • "India"
    • "Indonesia"
    • "Thailand"
    • "Rest of Asia-Pacific"]}
    • {"Rest of the World"=>["Middle East and Africa"
    • "South America"]}

    Industrial Controllers Application Outlook

    • Automotive
    • Manufacturing
    • Oil & Gas
    • Energy & Utilities
    • Water & Wastewater
    • Food Processing & Beverage
    • Aerospace & Aviation
    • Others

    Report Scope

    Report Attribute/Metric Details
    Market Size 2024 USD 160406.62 million
    Market Size 2035 305139.89 (Value (USD Million))
    Compound Annual Growth Rate (CAGR) 6.02% (2025 - 2035)
    Base Year 2024
    Market Forecast Period 2025 - 2035
    Historical Data 2018- 2022
    Market Forecast Units Value (USD Million)
    Report Coverage Revenue Forecast, Market Competitive Landscape, Growth Factors, and Trends
    Segments Covered Type, Control, Application and Region
    Geographies Covered Europe, North America, Asia-Pacific, and the Rest of the World
    Countries Covered The U.S, Germany, Canada, U.K., Italy, France, Spain, Japan, China, Australia, India, South Korea, and Brazil
    Key Companies Profiled National Instruments Corporation, Ascon Tecnologic, Siemens Ag, Mitsubishi Electric, General Electric, Omron Corporation, Red Lion Controls (spectris plc), B&R Industrial, Automation Gmbh (ABB Ltd), Schneider Electric, Abb Limited, Honeywell International Inc., Rockwell Automation, Emerson Electric Corporation, Yokogawa Electric Corporation, Kawasaki Heavy Industries, Ltd.
    Key Market Opportunities ·       AI and ML in process control systems (PLC) based applications
    Key Market Dynamics ·       The rising expense of labour, along with the enormous strain on businesses to fulfil deadlines, has resulted in increased factory automation
    Market Size 2025 170063.49 (Value (USD Million))

    Market Highlights

    Author
    Ankit Gupta
    Senior Research Analyst

    Ankit Gupta is an analyst in market research industry in ICT and SEMI industry. With post-graduation in "Telecom and Marketing Management" and graduation in "Electronics and Telecommunication" vertical he is well versed with recent development in ICT industry as a whole. Having worked on more than 150+ reports including consultation for fortune 500 companies such as Microsoft and Rio Tinto in identifying solutions with respect to business problems his opinions are inclined towards mixture of technical and managerial aspects.

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    FAQs

    How much is the Industrial Controllers market?

    The Industrial Controllers Market size is expected to be valued at USD 151327 Million in 2023.

    What is the growth rate of the Industrial Controllers market?

    The global market is projected to grow at a CAGR of 6.02% during the forecast period, 2024-2032.

    Which region held the largest market share in the Industrial Controllers market?

    Asia-Pacific had the largest share of the global market.

    Who are the key players in the Industrial Controllers market?

    The key players in the market are National Instruments Corporation, Ascon Tecnologic, Siemens Ag, Mitsubishi Electric, General Electric, Omron Corporation, Red Lion Controls (spectris plc), B&R Industrial, Automation Gmbh (ABB Ltd), Schneider Electric, Abb Limited, Honeywell International Inc., Rockwell Automation, Emerson Electric Corporation, Yokogawa Electric Corporation, Kawasaki Heavy Industries, Ltd.

    Which Type led the Industrial Controllers market?

    The Distributed Control Systems (DCS) category dominated the market in 2022.

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