Advanced Process Control Market Size, Share, and Trends 2024 to 2034

The global advanced process control system market size was valued at USD 1.96 billion in 2023 and is expected to reach USD 4.81 billion by 2033, expanding growth at a CAGR of 9.50% during the forecast period owing to the rising complexity of manufacturing and processing systems. 

Key Takeaways

• Asia Pacific led the global market with the highest market share of 34.72% in 2023.
• North America region is estimated to expand the fastest CAGR between 2024 and 2033.
• By product, the service segment has held the largest market share in 2023.
• By end-user, the oil & gas segment captured the biggest revenue share in 2023.

Advanced Process Control Market Size in the U.S. 2024 To 2033

The Asia Pacific advanced process control system market size accounted for USD 680 million in 2023 and is projected to hit USD 1,720 million by 2033, growing at a CAGR of 9.66% between 2024 and 2033.

The Asia Pacific captured the biggest revenue share of 34.72% in 2023. The Asia Pacific region's advanced process controls market is dominated by India and China. This is because infrastructure development is increasing and there is a high demand for energy-efficient production systems. APC development and continuous improvement are aimed at improving the performance of manufacturing processes, resulting in higher product quality. APC implementation contributes to improved process safety while also lowering environmental emissions. Using advanced software, the manufacturers can easily maintain the plant's operation.

North America is expected to grow at a high CAGR in the forecast period. Early adoption of automation across end-use industries in countries such as the United States and Canada has resulted in this region becoming a mature market for advanced process control solutions. High R&D investment, combined with stringent environmental regulations, is driving up demand for APC systems for sustainable manufacturing processes. Increasing E&P activities in the region's oil and gas sector will contribute to the growth of the North America Advanced Process Control market during the forecast period.

Growth Factors

The increasing demand in the end user industries such as pharmaceuticals, energy & power, mining, minerals, and metals and food & beverages will propel the growth of APC market. APS offers comprehensive process engineering design capabilities for aseptic, pasteurization, extended shelf life, hot fill, blending, batching, and CIP equipment to food and beverage producers. For instance, Tetra Pak is collaborating with Rockwell Automation to introduce model predictive control to powder manufacturing machines. Because of changing customer behavior and market needs, particularly in the food and beverage area, machine makers are seeking to manufacturing technology partners to give more complex automation options. Tetra Pak, a manufacturer of packaging and processing equipment for liquid food items as well as ice cream, cheese, fruit, vegetables, and pet food, followed suit. The OEM has announced a strategic business relationship with Rockwell Automation, the first step of which would focus on Tetra Pak's Cheese and Powder Solutions division. The collaboration for the advancement in the process technology will create a pressure on the rest market players in the industry which will proliferate the growth of the APC market.

Advanced Process Control Market Scope

Market Dynamics

Driver:

Customization and Scalability

Various sectors have distinct needs and procedures. For advanced process control solutions to meet these particular requirements, they must be adaptable. The specifications for APC in chemical manufacturing, for instance, could be very different from those in semiconductor manufacture. Even within the same industry, processes might differ greatly depending on raw materials, equipment setups, and ambient conditions. Through customization, advanced process control solutions can adjust to these changes and maintain maximum performance in a variety of process conditions. Scalability is provided via modular advanced process control solutions, which enable the addition or removal of components as needed. Organizations can grow their advanced process control deployments in response to shifting operational demands and resource limitations thanks to this modular methodology.

Restraint:

Data Privacy and Security Concerns

Large volumes of sensitive data, including trade secrets, proprietary information, and possibly personally identifiable information (PII) of personnel, are gathered and analyzed by advanced process control systems in relation to industrial operations. Stricter laws and compliance requirements pertaining to data privacy and security, such as the General Data Protection Regulation (GDPR) in Europe or industry-specific laws like the North American Electric Reliability Corporation (NERC) standards for the energy sector, are frequently applicable to industries using advanced process control systems. Workers with access to private systems and data may unintentionally reveal confidential information or intentionally abuse their privileges for sabotage or personal benefit. While access restrictions guarantee that only authorized people can view or edit crucial system parameters, encryption aids in preventing unwanted access to data.

Opportunity:

Industry 4.0 Integration

Large volumes of data can be collected from a variety of sources in the manufacturing environment, such as production lines, sensors, and equipment, thanks to Industry 4.0. advanced process control systems can use prescriptive and predictive analytics in conjunction with Industry 4.0 integration to proactively modify control settings in order to maximize performance and foresee possible process aberrations or breakdowns. IoT-enabled sensors and actuators in the context of advanced process control allow for remote access and management of manufacturing activities from any location in the world, in addition to real-time process monitoring and control. Because it offers scalable computing resources and storage capacities for managing massive volumes of data generated by advanced process control systems, cloud computing is essential to Industry 4.0 integration.

Product Insights

Based on the product, the market is subdivided into hardware, services, and software. Because of the large installed base of advanced process control systems in developed regions such as North America and Europe, the service type dominates the market. The service type is further classified into advanced regulatory control, multivariable model predictive control, inferential control, sequential control, and compressor control.

Model-predictive control is the most widely used automated multivariable control technology today (MPC). MPC distinguishes itself through the use of detailed process models, embedded optimizers, and a large-matrix approach to application design, in which dozens of variables and often hundreds of models emerge and evolve. 

End-User Insights

Based on the end-use industries, oil & gas took the largest share in 2023. The term "advanced process control" (APC) refers to a wide range of sophisticated technologies and tools used to optimize oil and gas plant performance in a variety of applications. It is used to improve plant performance and stabilize operations by reducing fluctuations in key process variables.

Advanced process control (APC) projects in the chemical industry have been shown to increase capacity by 3% to 5%. APC debottlenecking the process, or a portion of it, by reducing variability and operating closer to limits. This allows for higher production rates. The total global revenue of the chemical industry in 2019 was approximately 3.94 trillion US dollars. In 2014, the chemical industry's global revenue reached a record high of 5.4 trillion US dollars. The chemical industry is critical to the global economy. Such high growth in the chemical industry will create a positive impact on the APC market. 

Further, energy and power types are expected to grow at a high CAGR in the APC market. According to reports, energy savings from APC implementation range from 3% to 15%, depending on the process and current operations. Most of the time, utility management is a complex control issue that affects the entire site and, at times, the electric grid. These system applications can be designed to provide benefits by lowering utility costs by up to 60%. The system can also be used to optimize energy production, such as boiler loads, gas turbines, and so on.

Advanced Process Control Market Companies

• Schneider Electric
• Siemens
• Rudolph Technologies
• Aspen Technology, Inc.
• Emerson Electric Co.
• ABB
• Yokogawa Electric Corporation
• Panasonic Corporation
• Rockwell Automation, Inc.
• Honeywell International Inc.
• Control Soft

Segments Covered in the Report

By Product

• Hardware
  • Control Systems
  • Interface and Display
  • Computing Systems
  • Others
• Service
  • Advanced Regulatory Control
  • Multivariable Model Predictive Control
  • Inferential Control
  • Sequential Control
  • Compressor Control
• Software

By End-User

• Oil and Gas
• Chemicals
• Pharmaceuticals
• Energy & Power
• Mining, Minerals, and Metals
• Food & Beverages
• Others

By Geography

• North America
  • U.S.
  • Canada
• Europe
  • U.K.
  • Germany
  • France
• Asia Pacific
  • China
  • India
  • Japan
  • South Korea
• Rest of the World