Industrial Controllers Market Trends

Global Industrial Controllers Market Overview

Industrial Controllers Market Size was valued at USD 1,51,327 million in 2023. The Industrial Controllers market industry is projected to grow from USD 160406.62 Million in 2024 to USD 255991.5 million by 2032, exhibiting a compound annual growth rate (CAGR) of 6.02% during the forecast period (2024- 2032). The rising expense of labour, along with the enormous strain on businesses to fulfil deadlines are the key market drivers boosting the growth of the Industrial Controllers market.  

FIGURE 1: INDUSTRIAL CONTROLLERS MARKET SIZE 2018-2032 (USD MILLION)

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

Industrial Controllers Market Opportunity

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  The AI AND ML in process control systems (plc) based applications is expected to drive market growth.

  
  

Artificial intelligence (AI) and machine learning (ML) are becoming increasingly important in the industrial sector, notably in process control systems. Improved automation and process optimization enabled by these technologies boost output while decreasing costs and improving safety. AI and machine learning have the potential to have a big impact on PLC-based process control systems (PLCs).

PLCs are frequently utilised in the industrial sector to automate and manage a variety of activities. They are suited for usage in industrial applications due to their dependability and endurance. Conventional PLCs, on the other hand, have a limited ability to adapt to and learn from the process over which they are responsible. This is where artificial intelligence and machine learning come in helpful. Manufacturers can improve automation and process optimization by adding these technologies into PLC-based process control systems.

Predictive maintenance is a fundamental use of AI and ML in PLC-based process control systems. By using data and analytics to predict when an equipment or system is likely to fail, proactive maintenance can be arranged before a malfunction occurs. This can increase output while decreasing downtime dramatically. PLCs may look for patterns and trends that suggest when a failure is likely to occur by applying AI and ML algorithms to sensor data from the machines and systems they manage. As a result, downtime is reduced and total output is increased since maintenance employees may schedule fixes and replacements before a piece of machinery or a system fails.

Real-time anomaly detection is another application of AI and ML in PLC-based process control systems. Anomaly detection is a technique for detecting abnormal or unexpected behaviour in a system. This is significant in industrial settings because it may signal a process problem, such as malfunctioning machinery or an inappropriate process configuration. Anomalies in real-time sensor data can be detected by AI and ML systems, alerting operators to potential problems. This allows for immediate corrective action, lowering the likelihood of downtime and enhancing overall production.

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.

FIGURE 2: INDUSTRIAL CONTROLLERS MARKET, BY TYPE, 2022 VS 2032 (USD MILLION)

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

FIGURE 2: INDUSTRIAL CONTROLLERS MARKET, BY TYPE, 2022 VS 2032 (K UNITS)

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

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.

Industrial Controllers 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)

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.

Industrial Controllers Key Market Players& 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 include

• 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.

Industrial Controllers 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.

Industrial Controllers 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 Application Outlook

• Automotive


• Manufacturing


• Oil & Gas


• Energy & Utilities


• Water & Wastewater


• Food Processing & Beverage


• Aerospace & Aviation


• Others

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