Functional Safety Market Size and Share
Market Overview
| Study Period | 2019 - 2030 |
|---|---|
| Market Size (2025) | USD 7 Billion |
| Market Size (2030) | USD 11.53 Billion |
| Growth Rate (2025 - 2030) | 10.48% CAGR |
| Fastest Growing Market | Asia-Pacific |
| Largest Market | Europe |
| Market Concentration | Low |
Major Players
*Disclaimer: Major Players sorted in no particular order Image © Mordor Intelligence. Reuse requires attribution under CC BY 4.0. |
|
Functional Safety Market Analysis by Mordor Intelligence
The Functional Safety Market size is estimated at USD 7.00 billion in 2025, and is expected to reach USD 11.53 billion by 2030, at a CAGR of 10.48% during the forecast period (2025-2030). Solid demand arises from the way stricter global standards now intersect with Industry 4.0 roll-outs, forcing manufacturers to embed safety functions into core automation platforms from the concept stage. Heightened regulatory enforcement following incident investigations in oil, gas, and power facilities further boosts adoption, while rapid digitalization creates use cases that favor programmable safety logic over hard-wired relays. Vendors also benefit from the need to merge functional safety with enterprise cybersecurity, a trend reinforced by ISA/IEC 62443 guidelines that treat process safety and cyber resilience as two halves of the same discipline. As a result, solution providers that can validate SIL compliance and cyber-secure design in one offering win a clear competitive edge.
Key Report Takeaways
- By device type, safety sensors captured 28% functional safety market share in 2024, whereas programmable safety systems are forecast to expand at an 11.2% CAGR through 2030.
- By safety system, emergency shutdown systems held 24% of the functional safety market size in 2024, while high-integrity pressure protection systems are on track for an 11.1% CAGR to 2030.
- By services, testing, inspection, and certification dominated with 46% share of the functional safety market size in 2024; training and consulting services post the fastest 11.3% CAGR to 2030.
- By end-user industry, oil and gas accounted for 42% of the functional safety market share in 2024; pharmaceuticals register the highest 11.0% CAGR through 2030.
- By geography, Europe led with 29% of the functional safety market share in 2024, whereas Asia-Pacific is projected to grow at an 11.4% CAGR to 2030.
Global Functional Safety Market Trends and Insights
Drivers Impact Analysis
| Driver | ( ~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
|---|---|---|---|
| Stringent global safety regulations and standards | +2.8% | Europe and North America lead, global scope | Long term (≥ 4 years) |
| Industry 4.0 expansion and automation | +2.1% | APAC core, spill-over worldwide | Short term (≤ 2 years) |
| Incident-driven scrutiny in oil, gas, and power | +1.9% | Global, concentrated in producing regions | Short term (≤ 2 years) |
| Integration of safety with industrial cybersecurity | +1.6% | North America and EU, moving to APAC | Medium term (2-4 years) |
| SIL-certified AI/ML shutdown algorithms | +1.2% | North America and Europe first movers | Long term (≥ 4 years) |
| Safety-as-a-Service models for SMEs | +0.9% | Global, high traction in emerging markets | Medium term (2-4 years) |
| Source: Mordor Intelligence | |||
Stringent Global Safety Regulations and Standards
IEC 61508 now anchors product approvals across sectors, and the 2024 ISO 26262 update adds explicit AI and machine-learning guidance, forcing design-stage safety integration. [1]Underwriters Laboratories, “What to Expect with Version 3 of ISO 26262,” UL, ul.com Manufacturers seeking global market entry therefore require SIL-rated components and system-level validation, which sustains predictable demand for accredited testing laboratories. At the same time, the EU Machinery Directive, OSHA directives, and comparable rules in Japan and China have raised enforcement intensity. Coupled with rising penalties for non-compliance, these frameworks motivate enterprises to replace standalone relays with integrated, certificate-backed safety controllers to simplify audits and speed plant approvals.
Industry 4.0 Expansion Accelerates Safety System Integration
Digital transformation places operational data in the cloud, so safety functions must now talk natively to Ethernet-based networks while maintaining deterministic response times. Smart factories use digital twins for predictive shutdowns, and AI analytics spot sensor drift before it threatens SIL targets. Such use cases favor programmable logic that can accept multiple protocols and push diagnostics upstream to MES and ERP layers. Demand therefore tilts toward flexible safety PLCs and software frameworks that can be patched remotely without losing certification status.
Incident-Driven Scrutiny in Oil, Gas, and Power
High-profile refinery explosions and grid failures in 2024 led regulators to accelerate site audits, expanding mandatory proof-testing intervals and documentation depth. Operators responded by installing emergency shutdown and pressure protection systems with built-in audit trails that demonstrate compliance automatically. This scrutiny is most intense in offshore environments, where downtime penalties reach millions of USD per day, reinforcing adoption of HIPPS and integrated fire-and-gas detection that meets SIL 3 targets while trimming flare capacity requirements.
Integration of Functional Safety with Industrial Cybersecurity
Converged OT/IT architectures expose safety loops to cyber threats, so ISA/IEC 62443 guidelines now require authenticated communication and secure boot inside safety controllers. Vendors embed encryption and anomaly detection directly in safety firmware, ensuring fail-safe behavior even during cyber incidents. Multinational firms increasingly issue single RFPs that merge SIL and cybersecurity specifications, steering the market toward platforms evaluated to both IEC 61508 and IEC 62443.
Restraints Impact Analysis
| Restraint | ( ~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
|---|---|---|---|
| High upfront cost of SIL-certified systems | -1.8% | Emerging markets and SMEs worldwide | Short term (≤ 2 years) |
| Complex retrofitting of legacy facilities | -1.4% | North America and Europe mature assets | Medium term (2-4 years) |
| Shortage of certified functional safety engineers | -1.1% | Global, severe in APAC | Long term (≥ 4 years) |
| Liability ambiguity for OTA safety updates | -0.7% | Global, policy gaps in emerging regions | Medium term (2-4 years) |
| Source: Mordor Intelligence | |||
High Implementation Costs Challenge SME Adoption
Obtaining SIL 3 certification can add 15-25% to total project budgets because of rigorous third-party testing and documentation. Many SMEs defer upgrades or select lower SIL targets, slowing penetration in light industry and discrete manufacturing. [2]TUV SUD, “Functional Safety,” TUV SUD, tuvsud.com While subscription models help, capital intensity remains the leading brake on near-term growth, especially where local enforcement is still maturing.
Brown-Field Retrofitting Presents Complex Integration Challenges
Legacy plants often rely on proprietary networks and analog signals, so swapping in Ethernet-ready safety controllers requires expensive protocol bridges and staged cut-overs. North Sea operators report that live migration projects raise costs by up to 60% versus green-field builds. Vendors therefore develop retrofit kits and simulation tools to keep production running, yet the engineering burden still lengthens sales cycles.
Segment Analysis
By Device Type: Sensors Remain Core as Programmable Logic Gains Pace
Revenue from safety sensors accounted for the largest 28% share of the functional safety market size in 2024, reflecting their role as the primary link between physical hazards and control systems. Continuous improvements in optical resolution and self-diagnostics increase sensor reliability, letting manufacturers raise proof-test intervals and cut downtime. Adoption also rises in clean-room and food-grade environments where non-contact sensing minimizes contamination risk.
Demand for programmable safety systems is forecast to post an 11.2% CAGR through 2030, the fastest rate among device categories. As Industry 4.0 spreads, users favor software-configurable logic that can adapt to frequent product changeovers without rewiring cabinets. Platforms such as Omron’s Sysmac Studio cut programming time by 90%, easing the certified-engineer bottleneck. [3]Omron Corporation, “Sysmac Studio Cuts Safety Programming Time,” Omron, omron.com Final control elements, valves, actuators, and drives, also gain momentum because process industries are replacing aging mechanical governors with SIL-rated digital devices that support condition monitoring. Over the forecast horizon, integrated sensor-controller packages that streamline validation are likely to shift spend away from discrete components toward bundled solutions, reinforcing the trend toward platform providers.
Note: Segment shares of all individual segments available upon report purchase
By Safety Systems: ESD Leads but HIPPS Captures Faster Growth
Emergency shutdown (ESD) systems represented 24% of the functional safety market share in 2024, anchored in oil, gas, and chemical operations that need rapid isolation during process upsets. [4]Schlumberger, “High-Integrity Pressure Protection System (HIPPS),” Schlumberger, slb.com Market density is highest on offshore platforms and LNG trains where high-value assets and stricter codes compel multi-layered protection. Vendors continue to enhance diagnostics and voting architectures to meet SIL 3 with fewer I/O points, lowering lifecycle cost.
High-integrity pressure protection systems (HIPPS) are projected to grow at an 11.1% CAGR as deep-water projects adopt them to avoid oversized flare stacks and reduce emissions. Successful deployments on North Sea assets delivered USD 25 million in CAPEX savings, creating a robust ROI case. Burner management and turbomachinery controls maintain steady demand in power and refining, while fire-and-gas systems receive a boost from regulations mandating full coverage models that integrate flame, toxic gas, and heat detection into one analytics dashboard.
By Services: TIC Dominance Continues While Training Accelerates
Testing, inspection, and certification (TIC) providers captured 46% of 2024 service revenue because third-party validation remains mandatory for SIL declarations in most jurisdictions. Multinationals often prefer global TIC partners to streamline audits across plant networks, reinforcing market concentration among a handful of accredited bodies.
Training and consulting services are set to expand at an 11.3% CAGR as firms tackle the shortage of certified experts. TUV SUD alone trained 7,000 engineers in 2024, yet demand still outweighs supply, prompting larger end users to sign multi-year training retainers. Design, engineering, and maintenance contracts also grow as vendors shift toward lifecycle models that cover hazard analysis, proof-testing, and periodic recertification. Embedded remote-support packages, often delivered via subscription, are now bundled with controller sales, smoothing revenue for suppliers and lowering unplanned downtime for users.
Note: Segment shares of all individual segments available upon report purchase
By End-User Industry: Oil and Gas Dominant, Pharma Rises
Oil and gas applications held 42% share of the functional safety market size in 2024; regulatory requirements for dual-path shutdown logic and blow-down segregation keep spend robust even during price cycles. Offshore projects allocate up to 6% of total CAPEX to safety instrumented systems, generating steady base demand.
Pharmaceutical manufacturing is forecast to grow at 11.0% CAGR through 2030, the fastest among end users, as FDA 21 CFR Part 11 and Part 211.68 rules push plants toward validated electronic records and automated quality checks. Continuous process verification in biologics drives orders for SIL-rated sensors, while cleanroom robotics adoption boosts demand for embedded safety firmware certified to ISO 13849. Power generation, automotive, and food processing form the next tier, each modernizing legacy lines to satisfy corporate safety targets and worker-protection rules.
Geography Analysis
Europe retained the lead with 29% functional safety market share in 2024, underpinned by the EU Machinery Directive and widespread use of advanced automation in Germany, Italy, and the Nordic states. Adoption intensifies in renewable energy and offshore wind, where high-value assets and remote locations demand SIL 3-compliant shutdown devices capable of remote diagnostics. [5]Siemens Press Center, “Siemens Unveils Innovative Motor Management System,” Siemens, press.siemens.com
North America follows closely, supported by OSHA-driven worker-safety programs and extensive refining, petrochemical, and pharmaceutical capacity. The region also pioneers safety-cybersecurity convergence, helped by mature IT-OT integration skills and a deep bench of certified engineers. Federal stimulus for semiconductor fabs reinforces new installations of programmable safety platforms that meet both IEC 61508 and ISA/IEC 62443 requirements.
Asia-Pacific is poised for the fastest 11.4% CAGR to 2030. China’s ongoing manufacturing upgrade, alongside Japan’s precision robotics investments, spurs heavy purchases of programmable safety PLCs and smart light curtains. Southeast Asian nations adopt subscription-based safety services to meet rising workplace safety expectations without heavy CAPEX, while India’s new chemical-process safety guidelines bring green-field plants straight to SIL 2-plus specification levels. Middle East and Africa contribute incremental gains as NOC and IOC projects in Saudi Arabia, Qatar, and the UAE standardize HIPPS and advanced fire-and-gas detection on green-field LNG and hydrogen facilities.
Competitive Landscape
The functional safety market features moderate fragmentation. Rockwell Automation’s Logix SIS combines process control and SIL 3 safety in one chassis, cutting integration labor by 30% and signaling a shift toward single-platform architectures. Siemens, Emerson, and ABB push similar playbooks, embedding cybersecurity and digital-twin hooks to lock customers into ecosystem roadmaps.
Competition intensifies around AI-enabled analytics that promise lower false-trip rates. BlackBerry QNX partnered with Intel to deliver an IEC 61508 SIL 3-certified software stack aimed at robotics and discrete manufacturing, illustrating how cross-domain alliances accelerate time-to-market for newcomers. Cloud-hosted Safety-as-a-Service, targeted at SMEs, emerges as a white-space opportunity, with Honeywell’s 2025 Digital Suite showcasing proactive cyber defense layered over safety diagnostics to offer continuous compliance in subscription form.
Service differentiation now revolves around lifecycle support. TIC majors bundle training portals, remote proof-testing, and AI-driven documentation engines to hold mindshare. Meanwhile, retrofit specialists carve a niche by guaranteeing zero-downtime migrations for brown-field plants using staged cut-overs and temporary bypass logic. Startups attacking the AI rules-verification problem could become attractive acquisition targets for established vendors eager to add model-validation tools ahead of large-scale autonomous operations.
Functional Safety Industry Leaders
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Rockwell Automation Inc.
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Emerson Electric Company
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Honeywell International Inc.
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ABB Ltd
-
Yokogawa Electric Corporation
- *Disclaimer: Major Players sorted in no particular order
Recent Industry Developments
- June 2025: Honeywell introduced its AI-enabled Digital Suite that merges cyber proactive defense with OT security operations centers, aiming to shift customers from automation to autonomy while ensuring functional safety integrity.
- March 2025: Rockwell Automation showcased Emulate3D Factory Test at NVIDIA GTC 2025, emphasizing virtual commissioning to cut physical FAT time and derisk complex safety logic before site deployment.
- October 2024: BlackBerry QNX and Intel released a SIL 3-certified platform for industrial automation, positioning themselves to supply safety software foundations for Industry 5.0 environments that require human–machine collaboration.
- October 2024: Siemens unveiled the SIMOCODE M-CP motor-management device with Ethernet connectivity, reflecting strategy to embed advanced safety and diagnostics into compact form factors for crowded switchboards.
Global Functional Safety Market Report Scope
Functional safety is part of the overall safety of the system or piece of equipment, which depends on automatic protection. Functional safety systems are composed of electrical and electronic elements that are used for the fulfillment of safety functions in most of the related sectors in several industries, as there is a high risk of related injuries.
The functional safety market is segmented by device type (safety sensors, safety controllers/modules/relays, safety switches, programmable safety systems, emergency stop devices, final control elements, and other devices), safety systems (burner management systems, turbomachinery control systems, high-integrity pressure protection systems, fire and gas monitoring control systems, emergency shutdown systems, supervisory control data acquisition systems, and distributed control systems), end-user industry (oil & gas, power generation, food & beverage, pharmaceutical, automotive, and other end-user industries), and geography (North America, Latin America, Europe, Asia-Pacific, and the Middle East and Africa).
The market sizes and forecasts are provided in terms of value in USD for all the above segments.
| Safety Sensors |
| Safety Controllers/Modules/Relays |
| Safety Switches |
| Programmable Safety Systems |
| Emergency Stop Devices |
| Final Control Elements (Valves, Actuators) |
| Other Device Types |
| Burner Management Systems (BMS) |
| Turbomachinery Control (TMC) Systems |
| High-Integrity Pressure Protection Systems (HIPPS) |
| Fire and Gas Monitoring Control Systems |
| Emergency Shutdown Systems (ESD) |
| Supervisory Control and Data Acquisition (SCADA) Systems |
| Distributed Control Systems (DCS) |
| Testing, Inspection and Certification |
| Design, Engineering and Maintenance |
| Training and Consulting Services |
| Oil and Gas |
| Power Generation |
| Food and Beverage |
| Pharmaceutical |
| Automotive |
| Other End-user Industries |
| North America | United States | |
| Canada | ||
| Mexico | ||
| South America | Brazil | |
| Argentina | ||
| Rest of South America | ||
| Europe | Germany | |
| United Kingdom | ||
| France | ||
| Italy | ||
| Spain | ||
| Rest of Europe | ||
| Asia-Pacific | China | |
| Japan | ||
| India | ||
| South Korea | ||
| Singapore | ||
| Australia | ||
| Malaysia | ||
| Rest of Asia-Pacific | ||
| Middle East and Africa | Middle East | Saudi Arabia |
| United Arab Emirates | ||
| Rest of Middle East | ||
| Africa | South Africa | |
| Egypt | ||
| Rest of Africa | ||
| By Device Type | Safety Sensors | ||
| Safety Controllers/Modules/Relays | |||
| Safety Switches | |||
| Programmable Safety Systems | |||
| Emergency Stop Devices | |||
| Final Control Elements (Valves, Actuators) | |||
| Other Device Types | |||
| By Safety Systems | Burner Management Systems (BMS) | ||
| Turbomachinery Control (TMC) Systems | |||
| High-Integrity Pressure Protection Systems (HIPPS) | |||
| Fire and Gas Monitoring Control Systems | |||
| Emergency Shutdown Systems (ESD) | |||
| Supervisory Control and Data Acquisition (SCADA) Systems | |||
| Distributed Control Systems (DCS) | |||
| By Services | Testing, Inspection and Certification | ||
| Design, Engineering and Maintenance | |||
| Training and Consulting Services | |||
| By End-user Industry | Oil and Gas | ||
| Power Generation | |||
| Food and Beverage | |||
| Pharmaceutical | |||
| Automotive | |||
| Other End-user Industries | |||
| By Geography | North America | United States | |
| Canada | |||
| Mexico | |||
| South America | Brazil | ||
| Argentina | |||
| Rest of South America | |||
| Europe | Germany | ||
| United Kingdom | |||
| France | |||
| Italy | |||
| Spain | |||
| Rest of Europe | |||
| Asia-Pacific | China | ||
| Japan | |||
| India | |||
| South Korea | |||
| Singapore | |||
| Australia | |||
| Malaysia | |||
| Rest of Asia-Pacific | |||
| Middle East and Africa | Middle East | Saudi Arabia | |
| United Arab Emirates | |||
| Rest of Middle East | |||
| Africa | South Africa | ||
| Egypt | |||
| Rest of Africa | |||
Key Questions Answered in the Report
What is the projected value of the functional safety market by 2030?
The functional safety market size is forecast to reach USD 11.53 billion by 2030, reflecting a 10.48% CAGR over 2025-2030.
Which device category leads current spending?
Safety sensors command the largest share at 28% of 2024 revenue, underscoring their role as the frontline of hazard detection.
Which region will grow fastest during the forecast period?
Asia-Pacific is expected to post the quickest 11.4% CAGR through 2030, driven by manufacturing expansion in China and Japan.
Why is pharmaceutical manufacturing an attractive growth segment?
FDA rules that require validated electronic records push drug makers toward automated, SIL-rated systems, producing an 11.0% CAGR outlook for the segment.
How are vendors addressing the shortage of certified safety engineers?
Suppliers expand training services, offer automated configuration tools, and bundle Safety-as-a-Service subscriptions that reduce onsite engineering needs.
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