Programmable Logic Controller (PLC) Market to Grow by USD 3.01 Billion (2025-2029), Driven by Demand for Compact Automation Solutions, AI Impact Report - Technavio

Feb 04, 2025, 04:37 ET

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NEW YORK, Feb. 4, 2025 /PRNewswire/ -- Report with market evolution powered by AI - The global Programmable logic controller (PLC) market size is estimated to grow by USD 3.01 billion from 2025-2029, according to Technavio. The market is estimated to grow at a CAGR of 3.5% during the forecast period. Increasing demand for compact automation solutions is driving market growth, with a trend towards increasing focus on expanding capability of micro-plcs. However, growing market for industrial pc and dcs as alternatives to plcs poses a challenge. Key market players include ABB Ltd., Beckhoff Automation, Eaton Corp., Emerson Electric Co., Ependion AB, Festo SE and Co. KG, Furukawa Electric Co. Ltd., IDEC Corp., Infineon Technologies AG, Keyence Corp., Lenze SE, Mitsubishi Electric Corp., OMRON Corp., Panasonic Holdings Corp., Parker Hannifin Corp., Robert Bosch GmbH, Rockwell Automation Inc., Schneider Electric SE, Siemens, and Toshiba Corp..

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Programmable Logic Controller (PLC) Market Scope

Report Coverage

Details

Base year

2024

Historic period

2019 - 2023

Forecast period

2025-2029

Growth momentum & CAGR

Accelerate at a CAGR of 3.5%

Market growth 2025-2029

USD 3009.1 million

Market structure

Fragmented

YoY growth 2022-2023 (%)

3.4

Regional analysis

APAC, North America, Europe, Middle East and Africa, and South America

Performing market contribution

APAC at 35%

Key countries

US, China, Japan, Canada, Germany, UK, India, South Korea, France, and Italy

Key companies profiled

ABB Ltd., Beckhoff Automation, Eaton Corp., Emerson Electric Co., Ependion AB, Festo SE and Co. KG, Furukawa Electric Co. Ltd., IDEC Corp., Infineon Technologies AG, Keyence Corp., Lenze SE, Mitsubishi Electric Corp., OMRON Corp., Panasonic Holdings Corp., Parker Hannifin Corp., Robert Bosch GmbH, Rockwell Automation Inc., Schneider Electric SE, Siemens, and Toshiba Corp.

Market Driver

The Programmable Logic Controller (PLC) market is thriving, driven by the increasing adoption of computer control systems in various industries. Input and output devices are key components, with steel and energy industries leading the way. Industrial control systems rely heavily on electronic devices, including PLCs, to manage production processes, power systems, and sensor measurements in buildings. Trends include miniaturization of machinery, compact PLCs, and the integration of wind power and wind turbines. OTEK Corporation's LED technology and digital panel meters are noteworthy innovations. Automated machines, conveyor systems, and packaging systems also benefit from PLCs. Macroeconomic factors, such as auto sales and electrification of vehicles, impact market growth. Industrial verticals like aerospace, defense, chemical, energy utilities, food and beverages, and healthcare are major consumers. PLCs come in various sizes: small, medium-sized, and large. Hardware components include processors, power supplies, and memory. Software capabilities, service, and training are essential. Cyber threats, including malware, ransomware, phishing attacks, and industrial espionage, pose challenges. IIoT, Arduino, Opta, Finder, and microcontrollers are significant players. The Arm Cortex-M7 core and Cortex-M4 core are popular processors. Floating-point units (FPUs), Chrom-ART accelerators, and hardware JPEG accelerators enhance functionality. Relays and switch boxes offer multi-functionality, reducing machine downtime. Industry automation, smart factories, robots, and PC-based and cloud-based controllers are shaping the future.

Micro Programmable Logic Controllers (PLCs), also known as compact or small form factor PLCs, are gaining significant traction in the process and discrete industries for controlling standalone machinery. Their advantages, such as flexible programming, user-friendly operation, communication capabilities, and cost-effectiveness compared to traditional PLCs, are driving their adoption. Initially designed for small machinery with basic serial communication, recent innovations have expanded micro-PLCs' capabilities to manage large machines with high-speed communication, large program memory, and support for multiple communications. These advancements broaden their applications in industrial end-user segments.

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Market Challenges

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Segment Overview

This programmable logic controller (plc) market report extensively covers market segmentation by

1.1 Modular- Modular Programmable Logic Controllers (PLCs) consist of interchangeable modules that can be combined to create a customized automation solution. Unlike single-function PLCs, modular models offer versatility and can be adapted for various applications. Modular PLCs can be arranged in cabinets or mounted on rails for safety and security. These systems are larger and more costly than unitary PLCs but offer advantages such as ease of maintenance and repair, increased memory, and the ability to add multiple systems. Industries with complex processes, such as oil and gas, mining, and automotive manufacturing, are significant end-users of modular PLCs due to their expanded input/output capabilities. As plant complexity increases, modular PLCs are increasingly adopted for future expansion. Furthermore, their enhanced memory modules enable faster operation, contributing to the growth of the global PLC market during the forecast period.

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Research Analysis

The Programmable Logic Controller (PLC) market refers to the computer control systems used in industry automation to manage and automate various processes. These systems utilize input devices to receive data from sensors and output devices to control automated machines. The steel and energy industries heavily rely on PLCs for efficient production and error reduction. PLCs are built with electronic devices such as relays and switch boxes for multi-functionality. Machine downtime is minimized with these advanced systems. However, with the increasing integration of Information Technology in industrial control systems, cyber threats such as malware, ransomware, and phishing attacks pose significant risks. Modern PLCs incorporate advanced features like dual-core microcontrollers with Cortex-M4 cores, flash memory, and static RAM to enhance performance and security.

Market Research Overview

The Programmable Logic Controller (PLC) market encompasses computer control systems used in various industries for automating production processes. These systems utilize Input devices to receive data and Output devices to send control signals. Industries such as Steel and Energy are significant consumers, with PLCs used to manage power distribution, vibration, humidity, temperature, and electrical noise. Modular, Small, Medium-sized, and Large PLCs cater to diverse industrial verticals. Hardware components include Processors, Power supplies, and Software for programming and service, as well as Training. The Energy power and Oil & gas industries, Food & beverages, Pulp & paper, and Wind power sectors benefit from PLCs. Miniaturization of machinery leads to the development of Compact PLCs and the integration of Wind power, Wind turbines, and Sensor measurements. OTEK Corporation's LED technology and Digital panel meters are essential electronic devices. Automated machines may encounter Errors requiring Technicians' intervention. Relays and Switch boxes offer multi-functionality. Machine downtime is minimized through Industry automation, including Conveyor and Packaging systems. PC-based and Cloud-based controllers are emerging trends. Macroeconomic factors, Auto assembly processes, Smart factories, Robots, and the Electrification of vehicles impact the market. Cyber threats, Malware, Ransomware, Phishing attacks, and Industrial espionage pose challenges to IIoT systems. Aerospace & defense, Chemical, Energy utilities, Food & beverages, Healthcare, and various Industrial automation sectors utilize PLCs. Arduino, Opta, IIoT, Finder, and microcontrollers with Arm Cortex-M7 and M4 cores, Floating-point units (FPU), Chrom-ART accelerators, and Hardware JPEG accelerators are essential components. Flash memory and Static RAM are crucial for storage.

Table of Contents:

1 Executive Summary2 Market Landscape3 Market Sizing4 Historic Market Size5 Five Forces Analysis6 Market Segmentation

7 Customer Landscape8 Geographic Landscape9 Drivers, Challenges, and Trends10 Company Landscape11 Company Analysis12 Appendix

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SOURCE Technavio