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Machine Automation Controller Market

ID: MRFR/ICT/41198-HCR
200 Pages
Aarti Dhapte
October 2025

Machine Automation Controller Market Research Report: By Type (Programmable Logic Controller, Distributed Control System, Industrial PC, Soft PLC), By End Use Industry (Manufacturing, Automotive, Pharmaceutical, Food and Beverage, Energy and Utilities), By Application (Process Automation, Robotics, Machine Control, Assembly Line Automation), By Connectivity (Wired, Wireless, Hybrid) andBy Regional (North America, Europe, South America, Asia Pacific, Middle East and Africa)- Forecast to 2035

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Machine Automation Controller Market Summary

As per MRFR analysis, the Machine Automation Controller Market Size was estimated at 11.49 USD Billion in 2024. The Machine Automation Controller industry is projected to grow from 12.2 USD Billion in 2025 to 22.29 USD Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 6.21 during the forecast period 2025 - 2035.

Key Market Trends & Highlights

The Machine Automation Controller Market is poised for substantial growth driven by technological advancements and increasing automation demands.

  • The integration of IoT technologies is transforming operational efficiencies in the Machine Automation Controller Market.
  • North America remains the largest market, while the Asia-Pacific region is emerging as the fastest-growing area for automation solutions.
  • Programmable Logic Controllers dominate the market, yet Soft PLCs are rapidly gaining traction due to their flexibility and scalability.
  • Rising demand for automation in manufacturing and advancements in robotics are key drivers propelling market expansion.

Market Size & Forecast

2024 Market Size 11.49 (USD Billion)
2035 Market Size 22.29 (USD Billion)
CAGR (2025 - 2035) 6.21%

Major Players

Siemens (DE), Rockwell Automation (US), Schneider Electric (FR), Mitsubishi Electric (JP), Honeywell (US), Emerson Electric (US), ABB (CH), Bosch Rexroth (DE), Yaskawa Electric (JP)

Machine Automation Controller Market Trends

The Machine Automation Controller Market is currently experiencing a transformative phase, driven by advancements in technology and increasing demand for automation across various industries. As organizations strive for enhanced efficiency and productivity, the integration of sophisticated automation controllers has become paramount. These devices facilitate seamless communication between machinery and control systems, enabling real-time monitoring and data analysis. The growing emphasis on smart manufacturing and Industry Four-point-zero initiatives further propels the adoption of these controllers, as businesses seek to optimize operations and reduce operational costs. Moreover, the Machine Automation Controller Market is witnessing a shift towards more flexible and scalable solutions. Companies are increasingly favoring modular systems that can be easily adapted to changing production needs. This trend is indicative of a broader movement towards customization and personalization in manufacturing processes. Additionally, the rise of the Internet of Things (IoT) is influencing the market landscape, as interconnected devices enhance the capabilities of automation controllers. Overall, the Machine Automation Controller Market appears poised for continued growth, driven by innovation and the relentless pursuit of operational excellence.

Integration of IoT Technologies

The incorporation of Internet of Things (IoT) technologies into the Machine Automation Controller Market is reshaping operational frameworks. This integration allows for enhanced connectivity and data exchange between devices, leading to improved decision-making and predictive maintenance capabilities.

Shift Towards Modular Systems

A notable trend within the Machine Automation Controller Market is the increasing preference for modular systems. These adaptable solutions enable manufacturers to customize their automation setups, facilitating scalability and flexibility in response to evolving production demands.

Focus on Energy Efficiency

There is a growing emphasis on energy efficiency within the Machine Automation Controller Market. Companies are prioritizing solutions that not only optimize performance but also minimize energy consumption, aligning with sustainability goals and regulatory requirements.

Machine Automation Controller Market Drivers

Increased Focus on Safety and Compliance

The Machine Automation Controller Market is witnessing a heightened emphasis on safety and compliance standards across various sectors. As regulatory requirements become more stringent, manufacturers are compelled to adopt automation solutions that ensure adherence to safety protocols. Automation controllers are integral in monitoring and controlling processes to mitigate risks associated with human error. Recent statistics indicate that industries investing in safety automation technologies have seen a reduction in workplace accidents by up to 30%. This focus on safety not only protects employees but also enhances operational efficiency, making automation controllers indispensable. Furthermore, as companies strive to maintain compliance with international standards, the demand for reliable and robust machine automation controllers is expected to grow, reinforcing their critical role in modern manufacturing.

Emergence of Modular Automation Solutions

The Machine Automation Controller Market is experiencing a shift towards modular automation solutions, which offer flexibility and scalability to manufacturers. Modular systems allow companies to customize their automation setups according to specific needs, facilitating easier upgrades and maintenance. This trend is particularly appealing to small and medium-sized enterprises that may not have the resources for large-scale automation investments. Market data indicates that the modular automation segment is expected to grow at a rate of 6% annually, driven by the demand for adaptable manufacturing solutions. As industries seek to enhance their operational efficiency without incurring significant costs, the adoption of modular automation controllers is likely to rise. This shift not only supports innovation but also aligns with the broader trend of digital transformation in manufacturing.

Advancements in Robotics and AI Integration

The Machine Automation Controller Market is significantly influenced by advancements in robotics and artificial intelligence. The integration of AI into automation systems enhances the capabilities of machine controllers, allowing for more sophisticated decision-making processes. This trend is evident as industries adopt smart manufacturing practices, which are projected to account for a substantial portion of the market by 2026. The ability of automation controllers to process vast amounts of data in real-time enables manufacturers to optimize their operations and respond swiftly to market demands. Moreover, the collaboration between robotics and automation controllers is expected to create new opportunities for innovation, thereby driving market growth. As companies increasingly invest in AI-driven solutions, the demand for advanced machine automation controllers is anticipated to rise, reflecting a shift towards more intelligent manufacturing environments.

Rising Demand for Automation in Manufacturing

The Machine Automation Controller Market is experiencing a notable surge in demand due to the increasing need for automation in manufacturing processes. As industries strive for enhanced productivity and efficiency, automation controllers play a pivotal role in streamlining operations. According to recent data, the manufacturing sector is projected to grow at a compound annual growth rate of approximately 5.5% over the next five years. This growth is largely driven by the need for precision and consistency in production, which automation controllers facilitate. Furthermore, the integration of advanced technologies such as artificial intelligence and machine learning into automation systems is expected to further propel the market. As manufacturers seek to reduce operational costs and improve output quality, the reliance on machine automation controllers is likely to intensify.

Growing Adoption of Smart Manufacturing Practices

The Machine Automation Controller Market is being propelled by the growing adoption of smart manufacturing practices. As industries transition towards Industry 4.0, the need for interconnected and intelligent systems becomes paramount. Automation controllers serve as the backbone of these smart factories, enabling seamless communication between machines and systems. Recent market analyses suggest that the smart manufacturing sector is set to expand significantly, with automation technologies playing a crucial role in this transformation. The ability to collect and analyze data in real-time allows manufacturers to make informed decisions, optimize production processes, and enhance overall efficiency. As the trend towards smart manufacturing continues to gain momentum, the demand for advanced machine automation controllers is likely to increase, reflecting a shift towards more agile and responsive manufacturing environments.

Market Segment Insights

By Type: Programmable Logic Controller (Largest) vs. Soft PLC (Fastest-Growing)

The Machine Automation Controller Market is characterized by a diverse range of segment values, including Programmable Logic Controllers (PLCs), Distributed Control Systems (DCS), Industrial PCs, and Soft PLCs. Among these, PLCs dominate in market share due to their widespread adoption in industrial settings for controlling machinery and processes. Following PLCs, Distributed Control Systems hold a significant position, allowing for centralized control across various decentralized equipment. In contrast, Industrial PCs and Soft PLCs are emerging players, with Soft PLCs gaining traction due to their flexibility and cost-effectiveness.

Programmable Logic Controller (Dominant) vs. Soft PLC (Emerging)

Programmable Logic Controllers (PLCs) are recognized as the dominant force in the Machine Automation Controller Market, owing to their robust performance and reliability in industrial automation. They are integral in managing complex automated processes, making them indispensable in sectors like manufacturing and energy. In contrast, Soft PLCs represent an emerging trend, utilizing software to replicate the functionality of traditional PLCs but with enhanced versatility and scalability. They enable seamless integration with existing IT infrastructures and offer lower capital investment, appealing to small and medium-sized enterprises. The flexibility of Soft PLCs positions them for growth as industries increasingly pursue smarter and more adaptable automation solutions.

By End Use Industry: Manufacturing (Largest) vs. Automotive (Fastest-Growing)

In the Machine Automation Controller Market, the 'End Use Industry' segment is significantly dominated by manufacturing, which illustrates the largest share due to its widespread adoption in production processes. This sector benefits from advanced automation technologies, allowing for improved efficiency and reduced operational costs. Following manufacturing, the automotive industry showcases increasing utilization of automation controllers, driven by rapid technological advancements and the shift toward smart manufacturing. Growth trends in this segment illustrate a vibrant landscape, particularly within the automotive sector, which is currently recognized as the fastest-growing segment. Factors such as the rising demand for electric vehicles and automation solutions are propelling this growth. The pharmaceutical and food and beverage industries are also expanding their automation capabilities, driven by the need for compliance with stringent regulations and the push for operational efficiency.

Manufacturing: Dominant vs. Automotive: Emerging

The manufacturing sector stands as a dominant force in the Machine Automation Controller Market, characterized by its strong reliance on automated solutions for production line efficiency. This sector leverages various automation controllers to streamline operations, improve production speed, and ensure product quality. In contrast, the automotive industry is emerging as a key player, with a growing focus on innovative automation technologies to accommodate the developing automotive landscape. This includes electric and autonomous vehicles, which are driving the demand for sophisticated machine automation. Both sectors are crucial for the market's evolution, with manufacturing leading in adoption and automotive rapidly integrating new technologies to advance their operations.

By Application: Process Automation (Largest) vs. Robotics (Fastest-Growing)

In the Machine Automation Controller Market, the application segments are characterized by varied shares of demand and utilization. Process Automation holds the largest market share, driven by its essential role in enhancing operational efficiency across industries. This segment benefits from a wide adoption in sectors such as oil and gas, pharmaceuticals, and manufacturing, where precision and control are vital. Robotics, on the other hand, is emerging rapidly as the fastest-growing segment. The adoption of robotic systems is fueled by advancements in AI and machine learning, increasing demand for automation in manufacturing, and a shift towards smart factories. As industries strive for increased productivity and reduced labor costs, robotics is becoming a critical component of modern automation strategies.

Process Automation (Dominant) vs. Robotics (Emerging)

Process Automation is the dominant application in the Machine Automation Controller Market, characterized by significant adoption in critical industries such as pharmaceuticals, chemicals, and energy. This segment is essential for streamlining operations, improving productivity, and ensuring compliance with stringent regulatory standards. On the other hand, Robotics represents an emerging yet rapidly growing segment, driven by innovations in automation technologies and increasing investments in smart manufacturing. Robotics encompasses the use of automated machines for repetitive tasks, enhancing efficiency and reducing errors. The growth in this segment is attributed to the increasing complexity of manufacturing processes and the need for sophisticated automated solutions that can adapt to varying production requirements.

By Connectivity: Wired (Largest) vs. Wireless (Fastest-Growing)

In the Machine Automation Controller Market, the connectivity segment is dominated by wired solutions, which cater to a wide range of industries due to their reliability and established technology. These wired connections are preferred for their low latency and stability, particularly in environments requiring real-time responses, thus holding a significant share of the market. Conversely, wireless connectivity is gaining traction and is expected to capture an increasing portion of the market as industries seek flexibility and mobility in automation processes. This shift is driven by advancements in technology and the growing need for efficient remote monitoring and control systems.

Connectivity: Wired (Dominant) vs. Wireless (Emerging)

Wired connectivity remains the dominant force in the Machine Automation Controller Market, renowned for its reliability, speed, and security. It is widely utilized in industrial settings where uninterrupted data transmission is critical, including sectors like manufacturing and process automation. On the other hand, wireless connectivity is emerging rapidly, spurred by innovations in wireless technology and the increasing demand for mobility and ease of installation. It offers the advantage of greater flexibility, allowing for the deployment of automation solutions in locations where wiring is impractical. With the trend moving towards smart factories and IoT integration, wireless solutions are expected to become a vital component as industries adapt to changing technological landscapes.

Get more detailed insights about Machine Automation Controller Market

Regional Insights

The Global Machine Automation Controller Market was poised for steady growth across various regions, with North America leading the way, valued at 4.5 USD Billion in 2024 and projected to reach 8.5 USD Billion by 2035, showcasing its majority holding in the market due to strong technological advancements and manufacturing capabilities. Europe followed, valued at 3.0 USD Billion in 2024 and expected to grow to 6.0 USD Billion, emphasizing its significant role in automation solutions amidst increasing industrial activities.

The APAC region, valued at 2.5 USD Billion in 2024, experienced rapid expansion, projected to achieve 5.5 USD Billion by 2035, driven by rising investments in smart manufacturing.

In contrast, South America and MEA presented smaller market sizes of 0.8 USD Billion and 0.69 USD Billion in 2024, respectively, with projections of 1.5 USD Billion and 1.8 USD Billion in 2035, suggesting that while they had opportunities for growth, they dominated less in the Global Machine Automation Controller Market landscape. Overall, the regional segmentation highlighted varying growth rates and importance in the market, where established regions like North America and Europe had significant technological advancements that contributed to the market growth.

Machine Automation Controller Market Region

Source: Primary Research, Secondary Research, Market Research Future Database and Analyst Review

Machine Automation Controller Market Regional Image

Key Players and Competitive Insights

The Global Machine Automation Controller Market is characterized by rapid advancements in technology and increasing demand for automation solutions across various sectors. As industries strive for higher efficiency, flexibility, and precision, key players in this market are focusing on enhancing their product offerings to cater to the evolving needs of end-users.

The competitive landscape is marked by continuous product innovations, strategic partnerships, and expansions, which are pivotal in maintaining a competitive edge. Companies are integrating advanced features such as artificial intelligence, IoT connectivity, and real-time data analytics into their automation controllers to enhance functionality and usability, positioning themselves favorably in a market that is forecasted for significant growth.

Mitsubishi Electric is a prominent name within the Global Machine Automation Controller Market, well-regarded for its innovative and reliable solutions. The company boasts a diverse range of automation controllers that cater to different industrial applications, demonstrating its ability to adapt to market demands. Mitsubishi Electric combines cutting-edge technology with advanced engineering to ensure their products deliver high performance and adaptability in complex manufacturing environments. Their extensive global presence enhances their competitiveness, allowing them to effectively serve customers across various regions while providing localized support.

The company's strong focus on research and development promotes ongoing innovation, enabling it to not only meet but also anticipate the changing dynamics of the machine automation sector. Yaskawa Electric stands out as a significant competitor in the Global Machine Automation Controller Market, recognized for its high-quality products and comprehensive solutions tailored for automation processes.

The company has established a robust reputation for its drive and motion control technology, which forms the backbone of its automation controllers. Yaskawa Electric emphasizes energy efficiency and seamless integration into existing systems, which resonates well with modern manufacturing demands.

Their commitment to quality and customer satisfaction translates into strong market performance bolstered by a wide range of applications in manufacturing and robotics. With an ongoing emphasis on advancing its technological capabilities, Yaskawa Electric continues to enhance its position in the market, effectively addressing the industrial need for reliable and sophisticated automation controllers.

Key Companies in the Machine Automation Controller Market market include

Industry Developments

  • Q2 2024: Siemens launches new SIMATIC S7-1500 automation controller with integrated AI capabilities Siemens announced the launch of its next-generation SIMATIC S7-1500 automation controller, featuring integrated artificial intelligence functions for advanced machine automation and process optimization. The new controller is designed to enhance productivity and flexibility in manufacturing environments.
  • Q2 2024: Rockwell Automation and NVIDIA announce partnership to accelerate industrial automation with AI Rockwell Automation and NVIDIA entered a strategic partnership to integrate NVIDIA's AI and edge computing technologies into Rockwell's machine automation controllers, aiming to deliver smarter and more efficient industrial automation solutions.
  • Q2 2024: Mitsubishi Electric launches MELSEC iQ-R Series safety CPU module for machine automation controllers Mitsubishi Electric introduced a new safety CPU module for its MELSEC iQ-R Series machine automation controllers, enabling enhanced safety and compliance for industrial automation systems in manufacturing plants.
  • Q1 2024: ABB unveils new AC500-XC PLC for extreme conditions in machine automation ABB launched the AC500-XC programmable logic controller (PLC), designed for machine automation applications in harsh and extreme environments, expanding its portfolio for industrial automation customers.
  • Q1 2024: Yaskawa Electric opens new robotics and automation R&D center in Japan Yaskawa Electric Corporation inaugurated a new research and development center focused on robotics and machine automation controllers, aiming to accelerate innovation in industrial automation technologies.
  • Q2 2024: Emerson introduces PACSystems Edge Solutions for machine automation Emerson launched PACSystems Edge Solutions, a new suite of edge computing products designed to enhance the performance and connectivity of machine automation controllers in industrial settings.
  • Q2 2024: Schneider Electric launches Modicon M262 logic/motion controller for smart machines Schneider Electric announced the release of the Modicon M262 logic/motion controller, targeting OEMs and machine builders seeking advanced automation and connectivity for smart manufacturing applications.
  • Q1 2024: Honeywell launches Experion PKS ControlEdge PLC for process and machine automation Honeywell introduced the Experion PKS ControlEdge PLC, a new programmable logic controller designed to unify process and machine automation, offering improved integration and operational efficiency.
  • Q2 2024: B&R Industrial Automation unveils X20CP3687X machine controller with integrated OPC UA over TSN B&R Industrial Automation launched the X20CP3687X machine controller, featuring integrated OPC UA over TSN technology for real-time industrial communication and enhanced machine automation performance.
  • Q1 2024: Beckhoff Automation introduces CX5600 Embedded PC for machine control applications Beckhoff Automation released the CX5600 Embedded PC, a new compact controller designed for demanding machine automation and control applications, offering high performance and flexible connectivity.
  • Q2 2024: Omron launches NX502 automation controller for high-speed, high-precision machine control Omron Corporation announced the launch of the NX502 automation controller, engineered for high-speed and high-precision control in advanced manufacturing and machine automation environments.
  • Q2 2024: Fuji Electric releases MICREX-SX Series SPH3000 machine automation controller Fuji Electric introduced the MICREX-SX Series SPH3000, a new machine automation controller designed to improve processing speed and reliability for industrial automation systems.

Future Outlook

Machine Automation Controller Market Future Outlook

The Machine Automation Controller Market is projected to grow at a 6.21% CAGR from 2024 to 2035, driven by advancements in IoT, AI integration, and increased demand for automation.

New opportunities lie in:

  • Development of AI-driven predictive maintenance solutions
  • Expansion into emerging markets with tailored automation solutions
  • Integration of cybersecurity features in automation controllers

By 2035, the market is expected to be robust, driven by innovation and strategic expansions.

Market Segmentation

Machine Automation Controller Market Type Outlook

  • Programmable Logic Controller
  • Distributed Control System
  • Industrial PC
  • Soft PLC

Machine Automation Controller Market Application Outlook

  • Process Automation
  • Robotics
  • Machine Control
  • Assembly Line Automation

Machine Automation Controller Market Connectivity Outlook

  • Wired
  • Wireless
  • Hybrid

Machine Automation Controller Market End Use Industry Outlook

  • Manufacturing
  • Automotive
  • Pharmaceutical
  • Food and Beverage
  • Energy and Utilities

Report Scope

MARKET SIZE 202411.49(USD Billion)
MARKET SIZE 202512.2(USD Billion)
MARKET SIZE 203522.29(USD Billion)
COMPOUND ANNUAL GROWTH RATE (CAGR)6.21% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Billion
Key Companies ProfiledMarket analysis in progress
Segments CoveredMarket segmentation analysis in progress
Key Market OpportunitiesIntegration of artificial intelligence in Machine Automation Controller Market enhances operational efficiency and predictive maintenance.
Key Market DynamicsRising demand for automation in manufacturing drives innovation and competition in the Machine Automation Controller market.
Countries CoveredNorth America, Europe, APAC, South America, MEA

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FAQs

What is the projected market valuation of the Machine Automation Controller Market by 2035?

The Machine Automation Controller Market is projected to reach a valuation of 22.29 USD Billion by 2035.

What was the market valuation of the Machine Automation Controller Market in 2024?

In 2024, the overall market valuation was 11.49 USD Billion.

What is the expected CAGR for the Machine Automation Controller Market during the forecast period 2025 - 2035?

The expected CAGR for the Machine Automation Controller Market during the forecast period 2025 - 2035 is 6.21%.

Which companies are considered key players in the Machine Automation Controller Market?

Key players in the Machine Automation Controller Market include Siemens, Rockwell Automation, Schneider Electric, and Mitsubishi Electric.

What segment of the Machine Automation Controller Market is projected to grow the most by 2035?

The Programmable Logic Controller segment is projected to grow from 3.45 USD Billion in 2024 to 6.89 USD Billion by 2035.

How does the market for Industrial PCs compare to other segments in 2025?

In 2025, the Industrial PC segment is expected to grow from 2.15 USD Billion in 2024 to 4.3 USD Billion by 2035.

What is the projected growth for the Automotive end-use industry in the Machine Automation Controller Market?

The Automotive end-use industry is projected to grow from 2.5 USD Billion in 2024 to 5.0 USD Billion by 2035.

What are the expected valuations for wired and wireless connectivity segments by 2035?

The wired connectivity segment is expected to reach 8.83 USD Billion, while the wireless segment is projected to reach 6.67 USD Billion by 2035.

Which application segment is anticipated to have a notable increase in valuation by 2035?

The Assembly Line Automation application segment is anticipated to grow from 3.0 USD Billion in 2024 to 5.4 USD Billion by 2035.

What is the expected growth trajectory for the Food and Beverage end-use industry in the Machine Automation Controller Market?

The Food and Beverage end-use industry is expected to grow from 2.0 USD Billion in 2024 to 4.0 USD Billion by 2035.

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