Programmable logic controller Market – Global Industry Size, Share, Trends, Opportunity, and Forecast Segmented By Type (Modular PLC, Compact PLC, Rack PLC), By Industry (Automotive, Chemical & Petrochemical, Paper & Pulp, Energy & Utilities, Food & Beverages, Oil & Gas, Others), By Region & Competition, 2021-2031F

Forecast Period	2027-2031
Market Size (2025)	USD 14.74 Billion
CAGR (2026-2031)	5.12%
Fastest Growing Segment	Modular PLC
Largest Market	North America
Market Size (2031)	USD 19.89 Billion

Market Overview

The Global Programmable logic controller Market will grow from USD 14.74 Billion in 2025 to USD 19.89 Billion by 2031 at a 5.12% CAGR. A Programmable Logic Controller is a ruggedized industrial digital computer widely employed to monitor input devices and control output mechanisms based on a custom program for the automation of electromechanical processes. The global market is principally supported by the intensifying demand for industrial automation in the automotive and energy sectors as well as the critical need for operational efficiency to reduce manufacturing costs. These primary drivers are distinct from technological trends as they address the fundamental requirement for reliable control infrastructure rather than auxiliary digital features.

According to VDMA Robotics and Automation, in 2024, the German robotics and automation sector forecasted sales to reach 16.5 billion euros driven largely by demand from foreign markets. Despite this positive industrial activity, a significant challenge that could impede market expansion is the scarcity of a skilled workforce capable of programming and maintaining these increasingly complex control systems which limits the pace of adoption in developing regions.

Key Market Drivers

Accelerating adoption of Industry 4.0 and smart manufacturing initiatives is fundamentally reshaping the programmable logic controller landscape by shifting the focus from standalone machine control to interconnected industrial ecosystems. Modern production environments now require controllers that can process complex logic while simultaneously handling vast data streams for edge analytics and cloud integration. This transition compels manufacturers to invest heavily in advanced control systems that support open protocols and cybersecurity mandates, creating a cycle of hardware replacement and upgrades. According to Rockwell Automation, March 2024, in the '9th Annual State of Smart Manufacturing Report', 95% of manufacturers are using or evaluating smart manufacturing technology, a statistic that underscores the urgent necessity for modern PLCs capable of supporting these digital transformation strategies.

The rapid expansion of the electric vehicle and automotive manufacturing sectors further amplifies this demand as legacy assembly lines are aggressively retooled for electrification. Automotive producers utilize high-performance modular controllers to manage battery assembly and electric drivetrain production with extreme precision and speed. According to the International Energy Agency, April 2024, in the 'Global EV Outlook 2024', sales of electric cars are expected to reach around 17 million in 2024, a production volume that necessitates extensive automated infrastructure scaling. The financial magnitude of this demand for automation hardware is evident in the recent performance of major industry players. According to Siemens AG, in 2024, the Digital Industries segment reported third-quarter revenue of 4.9 billion euros, reflecting the sustained capital expenditure on industrial automation technologies.

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Key Market Challenges

The scarcity of a skilled workforce capable of programming and maintaining complex control systems presents a substantial obstacle to the growth of the programmable logic controller market. As industrial automation becomes more integrated, the requirement for technicians who possess specialized knowledge in PLC architecture and logic design increases. When manufacturers cannot find qualified personnel to manage these systems, they often delay the implementation of new automation infrastructure or limit the scale of their upgrades. This hesitation directly reduces the procurement volume of hardware units, as companies avoid investing in technology they cannot effectively operate or repair.

This labor shortage impacts operational continuity and restricts the adoption rate of modern control solutions. According to the National Association of Manufacturers, in the first quarter of 2024, approximately 65 percent of manufacturing leaders cited the inability to attract and retain a quality workforce as a primary business challenge. This persistent lack of available talent forces organizations to rely on existing legacy systems rather than upgrading to new programmable logic controllers, thereby slowing overall market expansion in key industrial sectors.

Key Market Trends

The adoption of Artificial Intelligence and Machine Learning within control logic is rapidly evolving from a theoretical concept to a core operational requirement for modern industrial automation. Unlike traditional controllers that rely on static, rule-based instructions, AI-enabled PLCs can execute adaptive algorithms that optimize process loops in real-time and predict anomalies before they cause downtime. This integration allows for the deployment of generative and causal AI models directly at the control layer, enabling systems to autonomously correct inefficiencies and accelerate logic generation for complex manufacturing sequences. The momentum behind this technological shift is evident in recent investment patterns across the sector. According to Rockwell Automation, June 2025, in the '10th Annual State of Smart Manufacturing Report', the number of manufacturing organizations investing in generative and causal artificial intelligence technologies increased by 12 percent year-over-year, reflecting a decisive move toward autonomous control strategies.

Simultaneously, the market is experiencing a fundamental shift toward Software-Defined and Virtual PLC architectures, decoupling control software from proprietary hardware constraints. This trend is driving the migration of control workloads onto general-purpose industrial edge servers and cloud-agnostic platforms, facilitating greater scalability and interoperability under standards such as IEC 61499. By virtualizing the controller, manufacturers can update logic remotely, reduce supply chain dependency on specific hardware components, and integrate IT-based development practices like DevOps into the operational technology environment. The financial success of major automation vendors pivoting toward these digital solutions underscores the viability of this architectural transition. According to Siemens AG, November 2025, in the company's fiscal year 2025 earnings release, the group reported a net income of 10.4 billion euros, representing a 16 percent annual increase that was attributed largely to substantial growth in its industrial software and digital product segments.

Segmental Insights

The Modular PLC segment is currently recognized as the fastest-growing category within the Global Programmable Logic Controller Market. This expansion is driven by the inherent scalability of these systems, which allows industrial operators to customize input and output modules according to specific processing requirements. Unlike compact alternatives, modular units facilitate the management of complex large-scale automation tasks found in the automotive and energy sectors. Consequently, the ability to expand memory and repair individual components without replacing the entire system supports their increasing adoption for high-performance industrial applications.

Regional Insights

North America maintains a dominant position in the Global Programmable Logic Controller Market due to the extensive adoption of industrial automation across the United States and Canada. This leadership is fueled by substantial investments in the automotive, oil and gas, and power generation sectors, which require robust control systems for operational efficiency. Additionally, strict adherence to safety and equipment standards established by the National Electrical Manufacturers Association encourages the continuous upgrading of industrial infrastructure. The focus on modernizing manufacturing facilities to support smart production initiatives further solidifies the high demand for these controllers within the region.

Recent Developments

• In November 2024, Rockwell Automation expanded its strategic collaboration with Microsoft to accelerate industrial transformation through advanced cloud and artificial intelligence solutions. Announced during the Automation Fair, this partnership involved integrating Microsoft’s Azure IoT Operations with Rockwell’s industrial automation expertise to streamline operations and enhance data insights. The collaboration introduced capabilities such as the FactoryTalk Design Studio Copilot, which utilized generative AI to simplify the design of automation systems. This initiative aimed to bridge the gap between physical industrial processes and digital applications, enabling manufacturers to achieve greater scalability, operational efficiency, and resilience in their production environments.
• In May 2024, Omron Automation announced a strategic partnership with NEURA Robotics to revolutionize manufacturing efficiency through AI-driven technologies. This collaboration resulted in the unveiling of the Omron intelligent Cognitive Robot (iCR) series, which was designed to seamlessly integrate with Omron's all-in-one Sysmac control platform. By combining cognitive robotic capabilities with the Sysmac programmable logic controller ecosystem, the companies aimed to remove usage barriers and enable complex operations such as autonomous 3D bin picking. The partnership highlighted the convergence of advanced robotics and industrial control systems, providing manufacturers with flexible solutions for addressing labor shortages and improving productivity.
• In April 2024, Siemens introduced the Simatic S7-1200 G2, marking the release of the first new generation of this programmable logic controller series in a decade. Launched at the Hannover Messe, the controllers were engineered to bridge the gap between operational technology and information technology by offering enhanced communication performance and efficient data processing. The S7-1200 G2 series featured integrated motion control capabilities and flexible machine safety solutions, allowing machine builders to control multiple coordinated axes. This product launch was part of the Siemens Xcelerator platform, aiming to optimize productivity and flexibility for versatile industrial automation applications.
• In March 2024, Schneider Electric unveiled its new Lexium RL 3 and RL 12 collaborative robots during the MODEX exhibition. These advanced robotic systems were designed to be controlled by Modicon motion controllers, which uniquely unified programmable logic controller (PLC), motion, and robotics functionalities onto a single hardware platform. This integration facilitated a seamless collaborative data flow from the shop floor to top-level management systems via the EcoStruxure architecture. The unified control solution enabled manufacturers to coordinate up to 130 axes from one processor, significantly enhancing production flexibility and sustainability while simplifying the automation architecture for smart manufacturing environments.

Key Market Players

• ABB Ltd
• Mitsubishi Electric Corporation
• Schneider Electric SE
• Rockwell Automation Inc.
• Siemens AG
• Honeywell International Inc.
• Omron Corporation
• Panasonic Corporation
• Robert Bosch GmbH
• Emerson Electric Co.

By Type	By Industry	By Region
Modular PLC Compact PLC Rack PLC	Automotive Chemical & Petrochemical Paper & Pulp Energy & Utilities Food & Beverages Oil & Gas Others	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

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

• Programmable logic controller Market, By Type:

• Modular PLC
• Compact PLC
• Rack PLC

• Programmable logic controller Market, By Industry:

• Automotive
• Chemical & Petrochemical
• Paper & Pulp
• Energy & Utilities
• Food & Beverages
• Oil & Gas
• Others

• Programmable logic controller 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