PC Based Automation Market - Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Components (HMIs, SCADA, PLC, DCS, Others), By Offerings (Hardware, Software, Others), By Sales Channel (Direct Sales, Indirect Sales), By Industry (Discrete Industry, Process Industry), By Region, By Competition 2021-2031F

Forecast Period	2027-2031
Market Size (2025)	USD 35.91 Billion
CAGR (2026-2031)	7.56%
Fastest Growing Segment	Process Industry
Largest Market	North America
Market Size (2031)	USD 55.61 Billion

Market Overview

The Global PC Based Automation Market will grow from USD 35.91 Billion in 2025 to USD 55.61 Billion by 2031 at a 7.56% CAGR. PC-based automation is defined as the utilization of open-architecture personal computer hardware and software to execute industrial control and monitoring tasks, serving as a flexible alternative to proprietary Programmable Logic Controllers. The primary driver supporting this market is the increasing necessity for seamless integration between operational technology and information technology, which facilitates the high-speed data processing and connectivity required for smart manufacturing. Furthermore, the inherent scalability of commercial off-the-shelf processors allows manufacturers to deploy complex control algorithms and visualization tools more cost-effectively than with traditional hardware, thereby enhancing overall production efficiency without significant capital expenditure.

However, a significant challenge impeding broader market expansion is the susceptibility of general-purpose operating systems to cybersecurity threats and stability issues, which requires rigorous maintenance to ensure deterministic real-time performance. Manufacturers must constantly mitigate these vulnerabilities to prevent costly operational disruptions in critical infrastructure. Despite these hurdles, investment in advanced control technologies remains resilient. According to VDMA Robotics + Automation, in 2024, the industry projected a turnover growth of 2 percent to 16.5 billion euros, driven primarily by international demand for sophisticated automation solutions. This reflects the continued reliance on the computational power and connectivity that PC-based architectures provide to the global industrial sector.

Key Market Drivers

Accelerated adoption of Industry 4.0 and Smart Manufacturing initiatives is fundamentally reshaping the market by necessitating robust computational platforms capable of handling vast data streams. Manufacturers are increasingly migrating from legacy systems to PC-based architectures that support complex connectivity and flexible software integration, which are essential for modernizing production lines. This shift is quantified by recent industry surveys indicating a near-universal move toward advanced technologies. According to Rockwell Automation, April 2024, in the '9th Annual State of Smart Manufacturing Report', 95% of manufacturers are now using or evaluating smart manufacturing technology, an increase from 84% the previous year. This high adoption rate underscores the critical role of PC-based controllers in facilitating the digital transformation strategies that prioritize efficiency and data transparency across the factory floor.

Surging deployment of Artificial Intelligence and Machine Vision systems further propels the demand for high-performance industrial PCs, as these applications require significant processing power at the edge to execute complex algorithms in real-time. PC-based automation provides the necessary open environment to integrate high-resolution cameras and deep learning models for tasks such as automated quality inspection and predictive maintenance. According to Zebra Technologies, June 2024, in the '2024 Manufacturing Vision Study', 66% of manufacturing leaders globally plan to implement machine vision solutions over the next five years to optimize quality and visibility. This technological integration translates into tangible market growth for specialized hardware providers. According to Beckhoff Automation, April 2024, in their annual financial announcement, the company reported a global turnover of 1.75 billion euros for the 2023 financial year, representing a 16% increase over the previous year, driven by the continued industrial demand for powerful PC-based control technologies.

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Key Market Challenges

The susceptibility of general-purpose operating systems to cybersecurity threats and stability issues constitutes a major impediment to the expansion of the PC-based automation market. Unlike proprietary controllers designed for isolated reliability, open-architecture systems require frequent updates to defend against evolving digital risks. This necessity for rigorous maintenance often conflicts with the industrial mandate for deterministic real-time performance, as system patches or background processes can introduce latency or force unexpected reboots. Consequently, manufacturers may hesitate to transition from traditional hardware, fearing that software vulnerabilities could lead to severe production stoppages or safety incidents in critical infrastructure.

This industry-wide apprehension regarding system integrity directly influences adoption rates. According to the SANS Institute, in 2024, 45 percent of operational technology professionals reported avoiding the use of cloud-based services and connected technologies specifically due to security and reliability concerns. This statistic highlights that despite the potential for enhanced connectivity, the inherent risks associated with open, PC-based architectures continue to restrict capital investment and slow the replacement of legacy systems in the global industrial sector.

Key Market Trends

The Adoption of Virtual PLCs and Software-Defined Control Systems is fundamentally altering the market by decoupling control logic from proprietary hardware, allowing manufacturers to run sophisticated automation on standard Industrial PCs (IPCs). This trend enables greater flexibility and interoperability, as operators can update control software without replacing physical infrastructure, effectively extending the lifecycle of PC-based assets while reducing hardware dependency. This shift towards hardware-agnostic solutions is gaining rapid industry traction. According to UniversalAutomation.org, June 2024, in the 'UniversalAutomation.org grows to 88 members' announcement, the organization reported that its membership had expanded to 88 stakeholders, driven by the accelerating industrial demand for portable, plug-and-produce automation software solutions.

Simultaneously, the Utilization of Industrial PCs for Digital Twin Simulations is becoming a critical component of modern production strategies, allowing companies to virtually validate processes before physical implementation. High-performance IPCs provide the necessary computational headroom to run these resource-intensive simulations locally, reducing downtime and optimizing production throughput through predictive modeling. This reliance on advanced virtualization tools is evidenced by recent adoption metrics. According to Universal Robots, November 2024, in the 'Survey Insights: How Manufacturers are Embracing Technology in 2024', 47% of manufacturers reported they are already employing digital technologies, including digital twins and IoT integration, to enhance operational resilience and drive efficiency across their production environments.

Segmental Insights

The Process Industry is the fastest-growing segment in the Global PC Based Automation Market, driven by the urgent shift toward digital transformation in sectors like oil and gas, chemicals, and pharmaceuticals. This expansion stems from the superior capability of PC-based systems to execute complex control algorithms and perform real-time data analytics, which are essential for continuous production. As manufacturers prioritize Industry 4.0, these solutions offer the necessary connectivity for enterprise integration and predictive maintenance. Furthermore, the increasing requirement for strict regulatory compliance and energy efficiency significantly fuels the adoption of this flexible technology.

Regional Insights

North America maintains a dominant position in the global PC-based automation market due to the widespread integration of smart manufacturing technologies within the United States and Canada. This leadership is primarily driven by established industrial sectors, including automotive and aerospace, which utilize open architecture systems for flexible process control. The market expansion is further supported by initiatives promoting the Industrial Internet of Things and standardization frameworks from bodies such as the National Institute of Standards and Technology. These factors create a favorable environment for enterprises seeking scalable software-based control solutions to modernize their existing production infrastructure.

Recent Developments

• In November 2025, B&R, a division of ABB, introduced the Automation PC 50A, an ultra-high-performance industrial computer designed to tackle the growing complexity of modern manufacturing. This new device was equipped with powerful processors, including support for Intel Core i9, and featured a scalable architecture compatible with advanced graphics and AI acceleration hardware. The product was specifically developed to manage data-intensive tasks such as real-time simulation, predictive maintenance, and visual inspection. With enhanced cyber security features and robust processing capabilities, the platform aimed to provide machine builders with a future-proof solution for adaptive and resilient industrial automation.
• In October 2025, Advantech launched the MIC-735, an edge AI system powered by the NVIDIA IGX Thor platform, to address the evolving needs of the industrial automation and robotics sectors. This high-performance computing solution was engineered to deliver real-time artificial intelligence processing and functional safety, making it ideal for autonomous mobile robots and smart factory applications. The system offered superior processing capabilities to handle heavy workloads, ensuring precise control and decision-making in dynamic environments. By integrating advanced AI and safety features, the company aimed to support the next wave of intelligent manufacturing and secure industrial operations.
• In November 2024, Siemens launched a new line of Industrial PCs (IPCs) integrated with NVIDIA GPUs, marking a significant expansion of its Industrial Operations X portfolio. This development was designed to accelerate the execution of artificial intelligence applications on the factory floor, offering a substantial increase in AI processing speed for demanding workloads. The collaboration aimed to democratize access to advanced industrial AI, allowing manufacturers to implement complex tasks such as robot picking and visual quality control without requiring extensive coding expertise. The ruggedized systems were built to withstand harsh industrial conditions while helping companies reduce costs and accelerate their digital transformation initiatives.
• In February 2024, Rockwell Automation released enhanced ASEM 6300 Industrial PCs, available in versatile box and panel configurations to support complex automation tasks. These new computing devices were engineered to integrate seamlessly with the FactoryTalk Optix software portfolio, enabling a flexible approach to human-machine interface design. The launch provided manufacturers with a scalable hardware platform featuring high-performance processors and extensive connectivity options to manage data-intensive operations. This initiative allowed users to deploy applications that interoperate effectively with both Rockwell and third-party controllers, fostering a more open, adaptable, and efficient industrial automation environment for diverse manufacturing sectors.

Key Market Players

• Siemens AG
• General Electric Company
• Mitsubishi Electric Corporation
• Schneider Electric SE
• Rockwell Automation Inc.
• ABB Ltd.
• OMRON Corporation
• Advantech Co. Ltd.
• Honeywell International Inc.
• Emerson Electric Co

By Components	By Offerings	By Sales Channel	By Industry	By Region
HMIs SCADA PLC DCS Others	Hardware Software Others	Direct Sales Indirect Sales	Discrete Industry Process Industry	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global PC Based Automation Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

• PC Based Automation Market, By Components:

• HMIs
• SCADA
• PLC
• DCS
• Others

• PC Based Automation Market, By Offerings:

• Hardware
• Software
• Others

• PC Based Automation Market, By Sales Channel:

• Direct Sales
• Indirect Sales

• PC Based Automation Market, By Industry:

• Discrete Industry
• Process Industry

• PC Based Automation Market, By Region:

• North America
• United States
• Canada
• Mexico
• Europe
• France
• United Kingdom
• Italy
• Germany
• Spain
• Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• South America
• Brazil
• Argentina
• Colombia
• Middle East & Africa
• South Africa
• Saudi Arabia
• UAE