Advanced Process Control Market, By Offerings (Hardware, Software, Services), By End-use Industry (Oil & Gas, Chemicals, Pharmaceuticals, Energy & Power, Mining & Minerals, Food & Beverages) & Forecast, 2024 – 2032

Advanced Process Control Market Size

Advanced Process Control Market was valued at USD 21.65 billion in 2023 and is estimated to register a CAGR of over 11% between 2024 and 2032.
 

Enhanced operational efficiency in brewery processes acts as a significant growth driver for the advanced process control (APC) market as it directly improves productivity by optimizing various stages of production such as fermentation, maturation, and filtration. This efficiency translates into reduced costs and higher throughput, which are crucial in competitive markets. APC enables breweries to maintain consistent product quality, meeting consumer expectations and regulatory standards more effectively. APC enhances the overall process visibility and control by integrating digital solutions, facilitating smarter decision-making and proactive maintenance, thereby driving further efficiency gains over time.
 

For instance, in February 2024, ABB launched new process automation solution for cold block stage of beer production to drive optimization and efficiency improvements. Brewery-specific ABB Ability BeerMaker for cold block intelligent process automation control solution will support safety and quality improvements, boost productivity, and raise operational efficiency.
 

APC helps minimize energy consumption in operations by optimizing process parameters in real-time. It ensures efficient process operation by continuously adjusting variables such as temperature, pressure, and flow rates to optimal levels. This reduction in energy consumption not only lowers operational costs but also aligns with global sustainability goals, making APC solutions attractive to industries facing stringent environmental regulations. APC's ability to achieve significant savings while enhancing productivity positions it as a crucial growth driver in the market for industries striving to improve their environmental footprint and economic efficiency simultaneously.
 

Implementing APC systems involves considerable capital expenditure. This includes costs for advanced hardware (sensors, controllers, and computing units), software licenses, integration services, and the necessary infrastructure upgrades. Such high capital requirements can be prohibitive, especially for small and medium-sized enterprises (SME) and even some larger companies with constrained budgets. Beyond the purchase price, the implementation of APC systems can incur additional costs related to customization, system integration, and potential downtime during installation. APC systems require regular maintenance, updates, and potential upgrades to stay effective and secure. The ongoing costs associated with these activities can be a deterrent for companies, particularly those with limited resources. These ancillary costs add to the overall financial burden, making the investment even more substantial and potentially deterring adoption.
 

Advanced Process Control Market Trends

APC systems are increasingly leveraging AI and ML algorithms to improve predictive modeling and decision-making capabilities. AI enables APC to analyze complex data patterns in real-time, optimizing process parameters for enhanced efficiency and quality. ML algorithms continuously learn from data, allowing APC systems to adapt and improve over time, making them invaluable for industries seeking precision and agility in their operations.
 

The adoption of cloud platforms in APC enables scalable and flexible deployment models. Cloud-based APC solutions facilitate remote monitoring, data storage, and analysis, allowing stakeholders to access real-time insights from anywhere. This approach reduces infrastructure costs, enhances collaboration across locations, and supports rapid deployment of updates and improvements. It also enables easier integration with other digital tools and technologies, fostering a more connected & responsive manufacturing environment.
 

Advanced Process Control Market Analysis

Based on the end-use industry, the market is segmented into oil & gas, chemicals, pharmaceuticals, energy & power, mining & minerals, food & beverages, and others. The oil & gas segment is expected to reach over USD 10 billion by 2032.
 

• Oil & gas operations involve highly complex processes such as refining, extraction, and distribution. APC systems can optimize these processes by ensuring precise control over variables, such as temperature, pressure, and flow rates, thereby enhancing efficiency and reducing operational costs.
   
• Stringent environmental regulations and safety standards in the oil & gas sector necessitate advanced control systems to ensure compliance. APC helps in achieving consistent compliance with regulatory requirements by maintaining operational parameters within specified limits.

Based on offerings, the market is segmented into hardware, software, and services. The hardware segment is expected to register a CAGR of over 12% during the forecast period.
 

• The development of advanced sensors and measurement devices has significantly improved the accuracy and reliability of data collection in industrial processes. High-precision sensors are essential for APC systems to monitor and control variables in real-time, driving the demand for sophisticated hardware components.
   
• The integration of Internet of Things (IoT) and Industrial Internet of Things (IIoT) technologies in industrial settings requires robust and advanced hardware to handle data acquisition, processing, and communication. This trend supports the growth of the hardware segment as industries invest in IoT-enabled devices and systems.

North America dominated the global advanced process control market in 2023 with over 35% of the total revenue share. The industries in North America, such as manufacturing, oil & gas, pharmaceuticals, and chemicals, are increasingly adopting APC solutions to enhance operational efficiency and maintain competitiveness in global markets. The region has a strong technological infrastructure and a high level of industrial automation readiness, supporting the implementation of sophisticated APC systems. Additionally, stringent regulatory standards in sectors, such as healthcare and environmental protection, drive the demand for APC technologies to ensure compliance and operational excellence.
 

The manufacturing, energy, pharmaceuticals, and chemical sectors in the U.S. are adopting APC technologies to improve productivity, reduce costs, and enhance product quality. There is a strong emphasis on innovations and technological advancement within these sectors, driving the adoption of advanced automation and control solutions. Additionally, regulatory requirements in areas, such as environmental protection and safety, necessitate the implementation of APC systems to ensure compliance and operational efficiency, further fueling market growth in the U.S.
 

APAC countries, including China, Japan, South Korea, and India, are witnessing rapid industrialization and infrastructure development, driving the demand for APC technologies to enhance operational efficiency and reduce costs in manufacturing and energy sectors. Additionally, increasing investments in industries, such as chemicals, pharmaceuticals, and food processing, are promoting the adoption of APC systems to improve product quality and compliance with international standards. Moreover, supportive government initiatives and technological advancements are further accelerating market growth in APAC.
 

The APC market is growing in Japan due to several key factors. Japan has a strong manufacturing base with industries, such as automotive, electronics, and chemicals, that require precise control and optimization of production processes, driving the adoption of APC technologies. There is a significant focus on innovations and technology advancement, with Japanese companies investing in automation and digital transformation initiatives. Additionally, stringent regulatory standards and a strong emphasis on quality control further stimulate the demand for APC solutions to ensure compliance and operational excellence in manufacturing operations across the country.
 

The APC market is expanding in South Korea primarily due to its robust industrial sector, which includes electronics, automotive, chemicals, and semiconductor manufacturing. These industries require advanced control technologies to optimize production processes, improve efficiency, and maintain high product quality standards. Additionally, South Korea's strong emphasis on technological innovations and industrial automation fosters the adoption of APC solutions. Furthermore, government initiatives to enhance manufacturing competitiveness and sustainability through digital transformation are driving the demand for APC technologies, positioning South Korea as a significant growth market in the APC sector.
 

Advanced Process Control Market Share

ABB Ltd. and Honeywell International Inc. held a share of over 5% in the advanced process control industry in 2023. ABB Ltd., headquartered in Switzerland, specializes in robotics, power, and automation technology. It offers advanced process control solutions that enhance operational efficiency across industries such as manufacturing, utilities, and transportation. The company focuses on digitalization and sustainability, providing integrated solutions that include AI-driven automation and robotics.
 

Honeywell, based in the U.S., is a diversified technology and manufacturing company. It provides APC solutions tailored to industries, such as aerospace, chemicals, and oil & gas, emphasizing safety, productivity, and energy efficiency. The company’s offerings integrate IoT, ML, and cloud technologies to optimize industrial processes globally.
 

Advanced Process Control Market Companies

Major players operating in the advanced process control industry are:

• ABB Ltd.
• Aspen Technology, Inc.
• Emerson Electric Co.
• General Electric Co.
• Honeywell International Inc.
• Schneider Electric SE
• Siemens AG
   

Advanced Process Control Industry News

• In May 2024, Södra Cell deepened has collaborated with ABB by selecting their advanced process control system to optimize operations at the Värö mill bleach plant. This partnership aimed to enhance efficiency and sustainability, leveraging data-driven decisions to drive digital transformation in Sweden’s leading pulp manufacturing facilities.
   
• In December 2023, ABB Ltd. launched Advanced Industrial Process Control with Ability Field Information Manager (FIM) 3.0. This digital solution provides industrial system engineers and facility maintenance crews with enhanced device connectivity and interoperability to boost productivity for process control instruments in the field. FIM 3.0 is designed to accommodate both existing and future smart factory devices to enable adaptability and digital transformation. The newly updated FIM 3.0 features a client/server architecture, facilitating simultaneous device management by multiple users, resulting in increased efficiency for configuring, commissioning, and maintaining field devices.
   

The advanced process control market research report includes in-depth coverage of the industry with estimates & forecasts in terms of revenue (USD Million) from 2021 to 2032, for the following segments:

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Market, By Offerings

• Hardware
• Software
  • Advanced regulatory control (ARC)
  • Multivariable model predictive control (MPC)
  • Inferential, sequential, and compressor control
  • Others
• Services

Market, By End-use Industry

• Oil & gas
• Chemicals
• Pharmaceuticals
• Energy & power
• Mining & minerals
• Food & beverages
• Others

The above information is provided for the following regions and countries:

• North America
  • U.S.
  • Canada
• Europe
  • Germany
  • UK
  • France
  • Italy
  • Spain
  • Rest of Europe
• Asia Pacific
  • China
  • India
  • Japan
  • South Korea
  • ANZ
  • Rest of Asia Pacific
• Latin America
  • Brazil
  • Mexico
  • Rest of Latin America
• MEA
  • UAE
  • Saudi Arabia
  • South Africa
  • Rest of MEA