Global Industrial Controller Market Size, Share, and Trends Analysis Report – Industry Overview and Forecast to 2031

Industrial Controller Market Analysis

The industrial controller market has experienced significant growth due to advancements in technology and innovative methodologies. One notable development is the integration of IoT (Internet of Things) technologies, which enables real-time monitoring and control of industrial processes. This has enhanced efficiency, allowing for predictive maintenance and reducing downtime.

In addition, the adoption of AI and machine learning in industrial controllers has improved decision-making processes, leading to optimized operations. These technologies facilitate adaptive control systems that can respond dynamically to changing conditions, thereby enhancing productivity and resource management.

Another critical advancement is the increased use of modular controllers, which provide flexibility in system design. These controllers can easily integrate with various devices, allowing manufacturers to customize their automation systems based on specific needs. The growth of Industry 4.0 has further propelled the demand for advanced industrial controllers. As industries increasingly focus on automation and data-driven insights, the market is projected to expand significantly.

Industrial Controller Market Size

The global industrial controller market size was valued at USD 106.03 billion in 2023 and is projected to reach USD 242.59 billion by 2031, with a CAGR of 10.90% during the forecast period of 2024 to 2031. In addition to the insights on market scenarios such as market value, growth rate, segmentation, geographical coverage, and major players, the market reports curated by the Data Bridge Market Research also include in-depth expert analysis, geographically represented company-wise production and capacity, network layouts of distributors and partners, detailed and updated price trend analysis and deficit analysis of supply chain and demand.

Industrial Controller Market Trends

“Integration of IoT in Industrial Controllers”

A integração da Internet das Coisas (IoT) está a impulsionar significativamente o crescimento no mercado dos controladores industriais. Os controladores habilitados para IoT permitem a monitorização de dados em tempo real, aumentando a eficiência operacional e reduzindo o tempo de inatividade. Por exemplo, a Siemens desenvolveu a série S7-1500, que incorpora tecnologia IoT para facilitar a comunicação perfeita entre máquinas e sistemas. Esta conectividade permite a manutenção preditiva, onde potenciais problemas podem ser identificados antes que levem a falhas, otimizando os processos de produção. À medida que as indústrias adotam cada vez mais práticas de fabrico inteligentes, espera-se que a procura por controladores industriais avançados que aproveitem as capacidades IoT aumente, criando oportunidades substanciais de crescimento no mercado.

Âmbito do relatório e segmentação do mercado de controladores industriais

Definição de mercado de controladores industriais

Um controlador industrial é um dispositivo especializado utilizado para gerir e regular processos, máquinas e equipamentos industriais. Estes controladores são parte integrante dos sistemas de automação, garantindo um controlo preciso sobre variáveis ​​como a temperatura, a pressão e o caudal. Os tipos comuns incluem Controladores Lógicos Programáveis ​​(PLCs), Sistemas de Controlo Distribuído (DCS) e sistemas de Controlo de Supervisão e Aquisição de Dados (SCADA). Os controladores industriais permitem a monitorização e análise de dados em tempo real, aumentando a eficiência e a produtividade. Apoiam vários setores, incluindo a indústria transformadora, o petróleo e o gás e a geração de energia, proporcionando um desempenho fiável em ambientes agressivos. As funcionalidades avançadas podem incluir conectividade para integração IoT e acesso remoto para gestão do sistema.

Dinâmica do mercado de controladores industriais

Motoristas

• Automação de Processos Industriais

A tendência crescente de automação na fabricação e produção impulsiona significativamente o mercado de controladores industriais. À medida que as indústrias procuram aumentar a eficiência e a produtividade, os controladores industriais desempenham um papel vital, permitindo um controlo preciso sobre as máquinas e os processos. Por exemplo, em maio de 2023, a OMRON Automation revelou o controlador industrial NX502, centrado na análise em tempo real e na otimização de processos. Este produto inovador visa aumentar a eficiência operacional, fornecendo medidas de segurança de alta velocidade, reduzindo significativamente os prazos de entrega nos processos de fabrico. Além disso, o NX502 foi concebido para maximizar a produtividade energética, oferecendo às empresas uma ferramenta poderosa para melhorar o desempenho e as operações sustentáveis ​​em ambientes industriais.

• Aumento da procura por fabricação inteligente

The shift towards smart manufacturing and Industry 4.0 significantly drives the industrial controller market. As manufacturers adopt advanced technologies, they require sophisticated controllers that can seamlessly integrate with IoT devices, sensors, and data analytics systems. For instance, In January 2023, B&R Industrial Automation GmbH launched the X2X+ backplane bus, an exciting new option that amplifies the performance of the existing X20 system by a factor of four. The compatibility of all current X20 I/O modules with the X2X+ ensures a seamless upgrade path. This innovation enables manufacturers to easily enhance their machinery's capabilities, providing a cost-effective solution for building more powerful and efficient machines.

Opportunities

• Integration of AI and Machine Learning

The integration of artificial intelligence (AI) and machine learning into industrial controllers presents significant market opportunities. These advanced technologies enhance decision-making through predictive analytics, enabling controllers to anticipate equipment failures and optimize maintenance schedules. For instance, Siemens’ SIMATIC controllers utilize AI algorithms to analyze real-time data from manufacturing processes, allowing for proactive adjustments that improve operational efficiency. This capability not only reduces downtime but also minimizes operational risks by ensuring optimal performance. As industries increasingly adopt smart manufacturing practices, the demand for AI-enabled industrial controllers is set to grow, driving innovation and investment in this technology sector.

• Rising Need for Customization and Flexibility

The increasing demand for customization and flexibility in manufacturing processes creates significant opportunities in the industrial controller market. Businesses are seeking controllers that can adapt to specific operational requirements, enabling them to produce a wider variety of products efficiently. For instance, in May 2022, Emerson Electric Co. introduced the PACSystems RSTi-EP CPE 200, a next-generation Programmable Automation Controller (PAC). This advanced controller is designed to support analytics, enabling end users to gain a competitive edge by enhancing efficiency, speed, and quality in their operations. With its robust features, the PACSystems RSTi-EP CPE 200 empowers industries to leverage data for informed decision-making and optimized performance.

Restraints/Challenges

• Complexity and Integration Issues

Complexity and integration issues significantly hinder the industrial controller market. Many organizations face challenges when attempting to integrate new controllers with existing machinery and systems. This process can be intricate and time-consuming, often requiring specialized knowledge and resources. Compatibility issues frequently arise, as legacy systems may not seamlessly interface with modern controllers, leading to increased project costs. These complications can result in implementation delays, causing disruptions in operations and prolonging return on investment timelines. Consequently, the difficulties associated with integration not only inflate project expenses but also deter organizations from adopting advanced industrial control solutions, ultimately restraining market growth.

• High Initial Investment

High initial investment is a significant restraint in the industrial controller market, particularly impacting small and medium-sized enterprises (SMEs). Upgrading to advanced industrial controllers involves substantial capital expenditure for equipment, software, and installation, which can be prohibitive for many SMEs. This financial burden discourages these businesses from modernizing their systems, leading to a reliance on outdated technologies that may not offer optimal efficiency or performance. As a result, the overall growth of the industrial controller market is limited, as a large segment of potential customers remains unable to invest in the necessary upgrades, stalling innovation and development within the industry.

This market report provides details of new recent developments, trade regulations, import-export analysis, production analysis, value chain optimization, market share, impact of domestic and localized market players, analyses opportunities in terms of emerging revenue pockets, changes in market regulations, strategic market growth analysis, market size, category market growths, application niches and dominance, product approvals, product launches, geographic expansions, technological innovations in the market. To gain more info on the market contact Data Bridge Market Research for an Analyst Brief, our team will help you take an informed market decision to achieve market growth.

Industrial Controller Market Scope

The market is segmented on the basis of type, component, application and control. The growth amongst these segments will help you analyze meagre growth segments in the industries and provide the users with a valuable market overview and market insights to help them make strategic decisions for identifying core market applications.

Type

• Programmable Logic Control (PLC)
• Distributed Control System (DCS)
• Supervisory Control and Data Acquisition (SCADA)
• Manufacturing Execution System (MES)
• Others

 Component

• Modular Terminal Blocks
• Relays and Optocouplers
• Surge Protectors
• Marking Systems
• Printing
• Ferulles Cable Lugs
• Handtools
• Testers
• Enclosure Products
• PCB Connectors and Terminals
• Heavy Duty Connectors
• Analog Signal Conditioner
• Electronics Housing
• Power Supplies
• Industrial Ethernet
• Remote IO

 Control

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

 Application

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

Industrial Controller Market Regional Analysis

The market is analyzed and market size insights and trends are provided by type, component, application and control as referenced above.

The countries covered in the market report are U.S., Canada, Mexico in North America, Germany, Sweden, Poland, Denmark, Italy, U.K., France, Spain, Netherland, Belgium, Switzerland, Turkey, Russia, Rest of Europe in Europe, Japan, China, India, South Korea, New Zealand, Vietnam, Australia, Singapore, Malaysia, Thailand, Indonesia, Philippines, Rest of Asia-Pacific (APAC) in Asia-Pacific (APAC), Brazil, Argentina, Rest of South America as a part of South America, U.A.E, Saudi Arabia, Oman, Qatar, Kuwait, South Africa, Rest of Middle East and Africa (MEA) as a part of Middle East and Africa (MEA).

North America is expected to dominate the industrial controller market due to government-favored policies promoting factory automation and a rising demand for intelligent and automated manufacturing systems. Key industries in the region, including automotive and aerospace, are increasingly adopting advanced technologies to enhance efficiency and productivity. This focus on innovation and automation is driving growth, positioning North America as a leader in the industrial controller sector.

Asia-Pacific is expected to show lucrative growth in the industrial controller market during the forecast period. This growth is driven by the rising trend of automation across various industries and innovative technological advancements in the region. Countries such as China and India are significantly investing in smart manufacturing and IoT technologies, further propelling demand for advanced industrial controllers to enhance operational efficiency and productivity.

The country section of the report also provides individual market impacting factors and changes in market regulation that impact the current and future trends of the market. Data points such as down-stream and upstream value chain analysis, technical trends and porter's five forces analysis, case studies are some of the pointers used to forecast the market scenario for individual countries. Also, the presence and availability of global brands and their challenges faced due to large or scarce competition from local and domestic brands, impact of domestic tariffs and trade routes are considered while providing forecast analysis of the country data.

Industrial Controller Market Share

The market competitive landscape provides details by competitor. Details included are company overview, company financials, revenue generated, market potential, investment in research and development, new market initiatives, global presence, production sites and facilities, production capacities, company strengths and weaknesses, product launch, product width and breadth, application dominance. The above data points provided are only related to the companies' focus related to market.

Industrial Controller Market Leaders Operating in the Market Are:

• National Instruments Corp. (U.S.)
• Ascon Tecnologic Srl (Italy)
• Siemens (Germany)
• Mitsubishi Electric Corporation (Japan)
• General Electric (U.S.)
• OMRON Corporation (Japan)
• Red Lion (U.S.)
• B&R (Austria)
• Schneider Electric (France)
• ABB (Switzerland)
• Honeywell International Inc. (U.S.)
• Rockwell Automation, Inc. (U.S.)
• Emerson Electric Co. (U.S.)
• Belden Inc. (U.S.)
• Kawasaki Heavy Industries, Ltd. (Japan)
• Yokogawa Electric Corporation (Japan)
• Hitachi Industrial Equipment Systems Co., Ltd. (Japan)
• IDEC Corporation (Japan)
• Koyo Electronics Industries Co., Ltd. (Japan)
• Delta Electronics, Inc. (Taiwan)

Latest Developments in Industrial Controller Market

• In May 2023, OMRON Automation unveiled the NX502 industrial controller, focusing on real-time analysis and process optimization. This innovative product aims to enhance operational efficiency by delivering high-speed safety measures, thereby significantly reducing lead times in manufacturing processes. Moreover, the NX502 is engineered to maximize energy productivity, offering companies a powerful tool for improved performance and sustainable operations in industrial environments
• In January 2023, B&R Industrial Automation GmbH launched the X2X+ backplane bus, an exciting new option that amplifies the performance of the existing X20 system by a factor of four. The compatibility of all current X20 I/O modules with the X2X+ ensures a seamless upgrade path. This innovation enables manufacturers to easily enhance their machinery's capabilities, providing a cost-effective solution for building more powerful and efficient machines
• In November 2022, Rockwell Automation enhanced its Allen-Bradley Micro850 and Micro870 2080-Lx0E controllers by integrating the latest version of the Connected Components Workbench software. This upgrade significantly boosts connectivity and design efficiency, featuring a new Class 1 implicit messaging capability. The improved controllers support up to eight EtherNet/IP devices, allowing for streamlined communication and control in various automation applications, ultimately increasing system performance and flexibility
• In September 2022, Hitachi, Ltd. announced its acquisition of Flexware Innovation, Inc., a manufacturing Systems Integrator (SI). This strategic move is set to enhance Hitachi’s business capabilities in North America, specifically in areas such as Manufacturing Execution Systems (MES), SCADA, Business Intelligence (BI), and ERP implementation. The acquisition aims to accelerate digitalization efforts alongside JR Automation, which specializes in robotic systems integration and automation solutions
• In May 2022, Emerson Electric Co. introduced the PACSystems RSTi-EP CPE 200, a next-generation Programmable Automation Controller (PAC). This advanced controller is designed to support analytics, enabling end users to gain a competitive edge by enhancing efficiency, speed, and quality in their operations. With its robust features, the PACSystems RSTi-EP CPE 200 empowers industries to leverage data for informed decision-making and optimized performance
• In April 2022, ABB and Ramboll entered into a memorandum of understanding to collaborate on new offshore substation opportunities within the global offshore wind sector. This partnership will leverage the expertise of both companies in the design and supply of electrical, automation, SCADA, and telecommunications equipment. Their combined efforts will enhance engineering, product development, installation, and operational maintenance, contributing to the growth and sustainability of offshore wind energy solutions

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