Advanced Process Control Market

Advanced Process Control Market Size

The global advanced process control market was valued at USD 3.5 billion in 2024 and is estimated to grow at a CAGR of 11.6% to reach USD 10.3 billion by 2034. The growth of the market is attributed to factors such as integration of AI, machine learning, and IoT into APC systems and growing adoption of automation and industry 4.0.

The rapid proliferation of AI, machine learning, and IoT into APC systems is one of the leading factors driving the demand for Advanced Process Control worldwide. Integrating AI, IoT, and Machine Learning into APC systems is already beginning to transform the industries to manage and optimize their processes. AI can improve APC’s predictive capabilities by analysing vast data and identifying patterns that human operators might miss. This leads to more accurate predictions and better control over manufacturing processes.

Additionally, IoT plays a critical role by providing a network of interconnected devices that continuously monitor and collect data from various points in the production process. This real-time data collection enables APC systems to make instantaneous adjustments, ensuring optimal performance and quality. Furthermore, Machine Learning algorithms can enhance APC by learning from past data to improve process control strategies. These algorithms can adapt to changing conditions and optimize processes without human intervention, improving efficiency and consistency.

For instance, in January 2024, ABB announced its plan to acquire majority of stake in software service provider company, Meshmind, with the purpose to enhance its Industrial IoT, Artificial Inteligence (AI), machine vision research and development capabilities. ABB is expected to bring together engineering expertise, AI, and software knowledge from this acquisition to establish a new global R&D center to enhance the development of cutting-edge automation solutions in its Machine Automation sector (B&R). 

Industry 4.0 shows the emergence of cyber-physical systems powered by advanced digital intelligence, transforming process industries that generate vast amounts of data from various instrumentation and control layers. To maximize automation benefits, advanced control measures are essential for managing complex processes, reducing variability, enhancing throughput, and supporting sustainability objectives. While process manufacturing has traditionally relied on feedback and feedforward regulatory controls, the shift toward Advanced Process Control (APC) introduces sophisticated techniques, statistical models, and mathematical methodologies to optimize operations by managing multiple variables simultaneously.

Advanced Process Control Market Trends

• As technology continues to evolve, so does the Advanced Process Control (APC) landscape and its role in quality assurance for high-precision industries. Emerging technologies such as Artificial Intelligence (AI), the Internet of Things (IoT), and Machine Learning are set to revolutionize APC systems, making them more efficient and effective.
  
• Advanced Process Control has proven to be an effective tool for improving operations by capturing the full process capabilities consistently.  However, the velocity of applying the technology as well as the sustainment of these significant benefits has been hampered by the usability of the software and adaptability of the applications.
  
• The adoption of advanced process control for oil and gas sector is another major trend supporting the growth of advanced process control market. In the oil and gas sector, production optimization is essential for enhancing output while minimizing costs. APC systems utilize real-time data analytics and predictive modelling to manage production processes more effectively. For instance, in reservoir management, APC can monitor and control parameters such as pressure, temperature, and flow rates. These systems can predict future production trends by analysing historical data and current conditions and adjust operations accordingly to maximize yield.
  

Advanced Process Control Market Analysis

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Based on the offering, the market is segmented into hardware, software and services.

• The hardware market accounted for USD 1.1 billion in 2024. APC enables to optimize the plant performance without changing the hardware. This makes APC solutions very cost effective. Large process revamps can increase the production capacity by 10% to 40% at the cost of sometimes a hundred million dollars/euros.
  
• The software market accounted for USD 1.6 billion in 2023. Empower operations to automatically increase production and yield whilst reducing consumables with Industrial Software that is flexible in terms of integration with existing advanced process control systems as well as customizable to tackle any control problem.
  

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Based on end-use industry, the market is divided into chemicals, energy & power, food & beverages, mining & minerals, oil & gas, pharmaceuticals, others.

• The chemicals market is expected to account for 20.7% of the global advanced process control market in 2024. In the chemical industry, a well-designed APC strategy aims to maximize margins while ensuring customer satisfaction by driving processes toward more efficient operating conditions. This enables continuous, safe, and reliable operation near peak profitability, maintaining consistency and efficiency daily.
  
• The oil & gas market is expected to account for 24.5% of the global market in 2024. The increased adoption of automation and the inherent nature of operations in this industry drive the demand for APC. Companies in this industry are using solutions that provide long-term benefits, such as enhanced efficiency, to boost profits without heavy investment. Oil corporations continue searching for innovative methods to lower expenses and improve profits while boosting annual production rates by implementing APC solutions. According to the Organization of the Petroleum Exporting Countries (OPEC), the global oil demand has experienced an increase by 2.5 million barrels per day (mb/d), year over year, to average 102.2 million barrels per day (mb/d) in 2023, surpassing the pre-pandemic levels.
  

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• In 2024, the U.S. advanced process control market accounted for USD 1.1 billion. The continuous focus of companies on innovations and technological developments in various sectors, demand for APCs in the U.S. has experienced significant growth in recent years. The stringent regulations associated with manufacturing practices and compliance requirements have developed growth in inclination towards adoption of advanced process control.
  
• The Germany advanced process control market is expected to reach USD 435.6 million by 2034. The growth of advanced process control in Germany is attributed to the strong industrial base and emphasis on precision manufacturing push industries to adopt cutting-edge APC technologies for process optimization, waste reduction, and sustainability.
  

• The China advanced process control market is expected to grow at a CAGR of 14.1% during the forecast period. Innovation in process controls and ongoing advancements in research are expected to improve the execution of controlled manufacturing operations, leading to enhanced product quality. Increase in safety control, reduction in emission, and elimination of unnecessary costs through embracing APCs have driven growth for this market in China.
  
• Japan is expected to account for a share of 14.6% of the advanced process control market in Asia Pacific. In Japan, the adoption of Advanced Process Control (APC) technologies is significantly enhancing industrial operations across various sectors. For example, Yokogawa Electric Corporation, a prominent Japanese company, has developed APC solutions that have been implemented in over 200 projects globally since their release in 2000. These solutions, including the Exasmoc multi-variable predictive optimizer, enable plant-wide optimization, maintaining optimal conditions to maximize production and profits.
  
• South Korea advanced process control market is expected to grow at a CAGR of 10% during the forecast period. In South Korea, the implementation of Advanced Process Control (APC) technologies is significantly enhancing industrial efficiency, particularly in the semiconductor sector. For example, Samsung Electronics pioneered the development of cutting-edge process technologies, including the 3-nanometer (nm) Gate-All-Around (GAA) architecture. This advancement has led to a 45% reduction in power consumption, a 23% improvement in performance, and a 16% decrease in surface area compared to the 5nm process.
  

Advanced Process Control Market Share

The advanced process control industry is competitive and highly fragmented with the presence of established global players as well as local players and startups. The top 7 companies in the global ambient light market are ABB Ltd., Honeywell International Inc., Siemens AG, Emerson Electric Co., Aspen Technology, Inc., General Electric Co., Schneider Electric SE, collectively accounting for a share of 35%. These companies are competing in the market by offering support for safety and quality improvements, boost productivity, and raise operational efficiency. For instance, In January 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.

New product launches are the most significant strategic development which key players in the market are adopting for augmenting their market share. Key Advanced Process Control manufacturers are increasingly launching new products for proliferation in industrial sectors. For instance, in August 2023, ABB implemented its advanced process control solution, the ABB Ability Expert Optimizer system, at the Tokuyama Nanyo cement plant in Japan. With the commissioning of the ABB Ability Expert Optimizer, Tokuyama can achieve a reduction of approximately 3% in thermal energy consumption in the kiln, all while upholding the operational quality at the Nanyo plant, recognized as one of Japan's largest single factories. This industrial software harnesses advanced process control techniques, including linear and non-linear model predictive control, fuzzy logic, and neural networks, to consistently and accurately automate optimal operational decisions.

Advanced Process Control Market Companies

The top 7 companies operating in the advanced process control industry are:

• ABB Ltd.
• Honeywell International Inc.
• Siemens AG
• Emerson Electric Co.
• Aspen Technology, Inc.
• General Electric Co.
• Schneider Electric SE
  
• ABB, a global company, specializes in the automation technology market and provides advanced process control solutions in different sectors. Their wide range of projects ensures successful implementation. ABB holds many process automation systems globally and distributes control systems for petrochemicals, oil & gas, refining, pulp and paper chemicals, and minerals.
  
• Emerson to Highlight Innovative Solutions for Sustainable Operations at EGYPES. For instance, in February 2024, Emerson Electric participated in the Egypt Energy Show (EGYPES) to present its advanced APC solutions focused on sustainability in energy production. These solutions underscore Emerson's commitment to enhancing operational efficiency and promoting sustainable practices within the energy sector, aligning with industry demands for greener, more resource-efficient processes.
  

Advanced Process Control Industry News

• In February 2024, GE Vernova, a subsidiary of General Electric Company, announced the release of Proficy, a novel software solution aimed at assisting manufacturers to attain sustainability goals, while enhancing productivity and profitability. The AI-powered software integrates operational and sustainability data to assist industrial companies in optimizing resource usage and ensuring regulatory compliance with climate metrics.
  
• In December 2023, Hollysys Automation Technologies Ltd and Ascendent Capital Partners announced the successful completion of their merger. This merger, involving Hollysys and entities affiliated with Ascendent, was carried out by the agreement and merger plan dated December 11, 2023. The agreement was made between the company, Superior Technologies Holding Limited, and its wholly owned subsidiary, Superior Technologies Merger Sub Limited.
  

This 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 2034, for the following segments:

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Market By Offerings

• Hardware        
  • Sensors
  • Control systems
  • Actuators and controllers
  • I/O modules and field devices
• Software          
  • Process control software
  • Optimization software
  • Data analytics and monitoring software
  • Cloud-based control and AI-driven solutions
• Services            
  • Consulting services
  • Integration services
  • Maintenance & support
  • Training and education

Market, By End Use Industry

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

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

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