Authored By: Sarah
27 Jan 2025

Programmable Logic Controller (PLC) Market Size Forecast: 2025-2029

The programmable logic controller (PLC) market is experiencing robust growth, with an expected increase of USD 3.01 billion at a CAGR of 3.5% between 2024 and 2029. PLCs have become integral in automating machines and processes across various industries, driving efficiency, productivity, and safety. This article delves into the key drivers, trends, challenges, and regional market insights shaping the future of the PLC market.

Global Programmable Logic Controller (PLC) Market 2025-2029

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Key Market Drivers

One of the primary factors fueling the growth of the PLC market is the increasing demand for compact automation solutions. As industries strive to streamline operations and minimize costs, PLCs offer an ideal solution for optimizing production processes. Additionally, the expanding capabilities of micro-PLCs are enabling businesses to perform more complex tasks, offering flexibility and ease of integration with other systems. This trend is enhancing the overall functionality of PLC systems and contributing to their growing adoption.

Furthermore, the shift toward the integration of Industrial Internet of Things (IIoT) systems, including PC-based and cloud-based controllers, is driving the demand for PLCs. These systems enhance operational efficiency by providing real-time monitoring, data analysis, and automation across various sectors.

Market Segmentation

By Product Type:

The PLC market can be segmented into several product types:

  • Modular PLCs: These systems offer adaptability with interchangeable modules and are primarily used in industries requiring numerous inputs and outputs, such as process control manufacturing. The modular segment is anticipated to witness significant growth during the forecast period, thanks to its versatility and cost-effectiveness in large-scale industrial applications.
  • Unitary PLCs: These PLCs offer a single, compact solution but with limited expansion capabilities compared to modular systems.
  • Rackmount PLCs: These systems offer flexibility in configuration and are used in larger-scale industrial processes.

The modular PLC segment was valued at USD 5.24 billion in 2019 and is expected to experience steady growth in the coming years.

By End-user Industry:

  • Process Industry: Industries such as steel, energy, oil and gas, food and beverages, and pulp and paper rely heavily on PLCs for industrial automation, monitoring, and control. PLCs help optimize machine operation, minimize downtime, and ensure energy efficiency.
  • Discrete Industry: PLCs play a crucial role in industries like automotive and aerospace, where they control discrete manufacturing processes.
  • Building Automation: With the rise in smart buildings, PLCs are increasingly used for controlling systems like lighting, HVAC, and security.

By Region:

  • APAC
    • China
    • India
    • Japan
    • South Korea
  • North America
    • Canada
    • US
  • Europe
    • Germany
    • UK
    • France
    • Italy
  • Middle East and Africa
  • South America

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Market Trends

  • Micro-PLCs: These compact devices are increasingly being adopted for controlling standalone machinery. Initially designed for small machinery, micro-PLCs have evolved to offer high-speed communication capabilities and multifunctionality, making them a cost-effective alternative to traditional PLCs. The integration of technologies such as AI, IoT, and microcontrollers is expanding their functionality, driving growth in sectors like steel, energy, and automotive.

  • Cybersecurity Concerns: As the use of IIoT systems grows, so does the risk of cyber threats, including malware, ransomware, and phishing attacks. Ensuring the security of PLC systems is becoming a top priority, with many businesses adopting stronger security protocols and conducting regular vulnerability assessments.

Challenges in the PLC Market

  • Competition from Industrial PCs and Distributed Control Systems (DCS): While PLCs continue to dominate industrial automation, the growing popularity of industrial PCs and DCS presents competition. These systems, with their advanced capabilities, are becoming viable alternatives to traditional PLCs in certain applications.

  • Cybersecurity Risks: As more industries integrate PLCs with IIoT technologies, the risk of cyberattacks has escalated. PLC systems need enhanced cybersecurity measures to mitigate threats such as malware, ransomware, and industrial espionage.

Key Players in the PLC Market

Several companies are leading the PLC market, employing strategies such as strategic partnerships, acquisitions, and product innovation to strengthen their market position. Some of the key 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
  • Toshiba Corp.

These companies continue to drive innovation in PLC technology, with a focus on enhancing hardware capabilities (e.g., processors, memory, and power supplies) and software functionality (e.g., floating-point units, Chrom-ART accelerators, and hardware JPEG accelerators).

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