Advanced Process Control Market Size & Share Analysis - Growth Trends & Forecasts (2024 - 2029)

The Advanced Process Control Market Report is Segmented by Type (Advanced Regulatory Control, Model Predictive Control, Inferential, Sequential, and Compressor Control), by End-User Vertical (Oil and Gas, Petrochemical, Pharmaceutical, Food and Beverage, Energy and Power, Chemical, Other End-User Verticals), and by Geography (North America, Europe, Asia-Pacific, Rest of the World). ​The Market Sizes and Forecasts are Provided in Terms of Value (USD) for all the Above Segments.

Advanced Process Control Market Size

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Advanced Process Control Market Summary
Study Period 2019 - 2029
Market Size (2024) USD 2.74 Billion
Market Size (2029) USD 4.10 Billion
CAGR (2024 - 2029) 8.38 %
Fastest Growing Market Asia Pacific
Largest Market North America

Major Players

Advanced Process Control Market Major Players

*Disclaimer: Major Players sorted in no particular order

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Advanced Process Control Market Analysis

The Advanced Process Control Market size is estimated at USD 2.74 billion in 2024, and is expected to reach USD 4.10 billion by 2029, growing at a CAGR of 8.38% during the forecast period (2024-2029).

Advanced process control (APC) describes techniques and tools for optimizing and controlling complex industrial processes such as power generation, chemical processing, manufacturing, or other methods. The objectives of APC are to enhance the efficiency, productivity, quality, security, and environmental performance of these processes. As APC requires complex algorithms and models to manage the complicated dynamics of a process, its processing control techniques are characterized by their higher levels of sophistication than in the case of traditional process control systems.

Although the concept of APC has existed for over thirty years, it has only recently gained prominence as factory units worldwide increasingly focus on process optimization. Given the growing complexity of industrial processes, operators' difficulties in carrying out manual controls have increased.

Integrating advanced technologies such as (IoT), extensive data analysis, and AI is a characteristic feature of Industry 4.0. Industry 4.0 is already being adopted in several countries.

Increased government initiatives to increase automation adoption will support the development of modern technologies, production centers, and innovation. Governments worldwide have implemented various national policies and initiatives to promote the use of blockchain, AI, the Internet of Things, and robotic systems in manufacturing operations. The initiatives by various governments to foster global investment and cooperation on business expansion have also generated positive momentum for some established companies. Therefore, the demand for advanced process controls is predicted to rise due to these benefits.

The industrial sector is looking for ways to improve the efficiency of its production processes. The growing awareness of the usage and need for energy savings, along with reduced greenhouse gas emissions, has contributed to this. Advanced process control solutions help reduce costs and improve sustainability to optimize energy consumption and reduce waste. Thus, it is expected that there will be opportunities in a developed market for process control because of a growing focus on energy efficiency by the different sectors, such as oil and gas, chemicals, or power generation.

However, implementing new technological solutions is limited due to stringent legislation and compliance in some sectors, e.g., pharmaceuticals and food and drinks, which hinder growth in the advanced process control market.

Advanced Process Control Market Trends

Oil and Gas is Expected to be the Largest Segment

  • The oil and gas sector is expected to hold a significant market share of the advanced process control market. The demand for APC is supported by higher rates of automation adoption and the fundamental nature of operations in this sector.
  • Following a sharp fall in oil prices last year, the industry is now focused on improving efficiency and deferring investment in new projects to the development of existing infrastructure.
  • In order to increase revenues with limited investment, companies in this sector are increasingly adopting solutions that offer various long-term benefits, such as increased efficiency. Oil companies still seek advanced processes that reduce costs and improve profitability with annual production increases.
  • According to OPEC, the global demand for crude oil (including biofuels) in 2023 amounted to 102.21 million barrels per day. Oil demand was expected to pick up by the end of the year, with forecasts suggesting it could increase to more than 104 million barrels per day. Concurrently, the demand for advanced process control systems is expected to increase during the forecast period.
Advanced Process Control Market : Crude Oil Demand, In Million Barrels Per Day, Global  from 2015-2024

North America Holds the Largest Market Share

  • In North America, the construction of new power stations, the presence of major semiconductor manufacturing sectors, and a growing demand for automation are anticipated to facilitate the adoption of APC systems.
  • Energy recovery in the United States is underway. Technological advances in hydraulic fracturing and drilling of shale formations have led to an increase in oil and gas production.
  • It also has the world's largest installed nuclear capacity and is the world's biggest producer of nuclear energy. Of the 99 nuclear reactors in 31 states, around 20% of electricity in the United States comes from them.
  • The demand for APC systems is increasing significantly in the region as nuclear power plants become more reliable through advanced process control systems.
  • Hardware components of the APC system include controls, computers, and electronic systems that allow effective monitoring and feedback via smart sensors. The growing use of APC systems in chemical and petrochemical industries across the region is expected to drive the growth of these components in the near future.
Advanced Process Control Market : Market CAGR (%), By Region, Global

Advanced Process Control Industry Overview

The advanced process control market is semi-consolidated, with the presence of several major players and small players. Major players apply strategic initiatives, such as acquisitions, collaborations, partnerships, expansions, and technology launches, to gain a competitive advantage over competitors and retain their market positions. Many players are investing in R&D to develop a cost-effective product portfolio.

  • In February 2024, ABB introduced a solution tailored for the cold block stage, aiming to enhance breweries’ operational efficiency along with the brewing process and facilitate the adoption of digital solutions and processes, including fermentation, maturation, yeast management, filtration, bright beer tanks area, etc.
  • In February 2024, Schneider Electric, in collaboration with Intel and Red Hat, announced that industrial companies could move to a software-defined, plug-and-produce solution that enables them to improve their operations, ensure quality, reduce complexity, and optimize their costs by releasing a distributed control node (DCN) software framework and a new framework.

Advanced Process Control Market Leaders

  1. ABB Ltd.

  2. Emerson Electric Co.

  3. Honeywell International Inc.

  4. Aspen Technology Inc.

  5. General Electric Co.

*Disclaimer: Major Players sorted in no particular order

Advanced Process Control Market Concentration
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Advanced Process Control Market News

  • December 2023: Schneider Electric collaborated with National Power Investment Group Digital Technology Co. Ltd (hereafter referred to as "Power Investment Digital Division") to jointly explore the smart aluminum (electrolytic aluminum, alumina) market. As part of the agreement, Schneider Electric and Power Investment Data will collaborate extensively in smart factories and smart manufacturing based on their vast accumulation and application experience in new-generation information technology and digital technology.
  • October 2023: ABB launched the advanced process control solution ABB Ability™ Expert Optimizer system to monitor, stabilize, and optimize industrial processes for the Tokuyama Nanyo cement plant in Japan. At the Nanyo plant, one of the largest in Japan, the installation of ABB Ability™ Expert Optimizer enables Tokuyama to reduce the thermal energy consumption of the kiln by approximately 3% and maintain the quality of production.

Advanced Process Control (APC) Market Report - Table of Contents

  1. 1. INTRODUCTION

    1. 1.1 Study Assumptions and Market Definition

    2. 1.2 Scope of the Study

  2. 2. RESEARCH METHODOLOGY

  3. 3. EXECUTIVE SUMMARY

  4. 4. MARKET INSIGHTS

    1. 4.1 Market Overview

    2. 4.2 Value Chain Analysis

    3. 4.3 Industry Attractiveness - Porter's Five Forces Analysis

      1. 4.3.1 Threat of New Entrants

      2. 4.3.2 Bargaining Power of Suppliers

      3. 4.3.3 Bargaining Power of Buyers/Consumers

      4. 4.3.4 Threat of Substitute Products

      5. 4.3.5 Intensity of Competitive Rivalry

  5. 5. MARKET DYNAMICS

    1. 5.1 Market Drivers

      1. 5.1.1 Increasing Demand for Automation Solutions across Various Industries

      2. 5.1.2 Rising Safety and Security Concerns are Expected to Boost the Demand for APC Systems

      3. 5.1.3 Inclination of Enterprises Toward Energy-efficient Processes

    2. 5.2 Market Restraints

      1. 5.2.1 Associated Complexities Challenge the Market Growth

  6. 6. TECHNOLOGY SNAPSHOT

  7. 7. MARKET SEGMENTATION

    1. 7.1 By Type

      1. 7.1.1 Advanced Regulatory Control

      2. 7.1.2 Model Predictive Control

      3. 7.1.3 Inferential, Sequential, and Compressor Control

    2. 7.2 By End-user Vertical

      1. 7.2.1 Oil and Gas

      2. 7.2.2 Petrochemical

      3. 7.2.3 Pharmaceutical

      4. 7.2.4 Food and Beverage

      5. 7.2.5 Energy and Power

      6. 7.2.6 Chemical

      7. 7.2.7 Other End-user Verticals

    3. 7.3 By Geography***

      1. 7.3.1 North America

        1. 7.3.1.1 United States

        2. 7.3.1.2 Canada

      2. 7.3.2 Europe

        1. 7.3.2.1 United Kingdom

        2. 7.3.2.2 Germany

        3. 7.3.2.3 France

      3. 7.3.3 Asia

        1. 7.3.3.1 China

        2. 7.3.3.2 India

        3. 7.3.3.3 Japan

      4. 7.3.4 Australia and New Zealand

      5. 7.3.5 Latin America

      6. 7.3.6 Middle East and Africa

  8. 8. COMPETITIVE LANDSCAPE

    1. 8.1 Company Profiles*

      1. 8.1.1 ABB Ltd

      2. 8.1.2 Aspen Technology Inc.

      3. 8.1.3 Emerson Electric Co.

      4. 8.1.4 General Electric Co.

      5. 8.1.5 Honeywell International Inc.

      6. 8.1.6 Rockwell Automation Inc.

      7. 8.1.7 Rudolph Technologies Inc.

      8. 8.1.8 Schneider Electric SE

      9. 8.1.9 Siemens AG

      10. 8.1.10 Yokogawa Electric Corp.

  9. 9. INVESTMENT ANALYSIS

  10. 10. MARKET OPPORTUNITIES AND FUTURE TRENDS

**Subject to Availability
***In the final report, Asia, Australia, and New Zealand will be studied together as 'Asia Pacific' and Latin America and Middle East and Africa will be considered together as 'Rest of the World'
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Advanced Process Control Industry Segmentation

Advanced process control is the supervisory level of process control, and it optimizes the functioning of process units in real time. This program is used to predict and control process behavior through mathematical models, algorithms, or statistical analyses, usually carried out on a computer network and via an interface in the control room. APC applications optimize the plant by controlling lower-level regulatory controllers while maintaining safety measures, with minimal change to the regulatory control system. The APC application, which drives the plant in a safe, dynamic, and responsive way, provides informed suggestions from decision-making models such as artificial intelligence, machine learning, and digital twins.

The advanced process control market is segmented by type (advanced regulatory control, model predictive control, inferential, sequential, and compressor control), end-user vertical (oil and gas, petrochemical, pharmaceutical, food and beverage, energy and power, chemical, other end-user verticals), and geography (North America (United States and Canada), Europe (United Kingdom, Germany, France, and Rest of Europe), Asia-Pacific (China, India, Japan, and Rest of Asia-Pacific), and Rest of the World). The market sizes and forecasts are provided in terms of value (USD) for all the above segments.

By Type
Advanced Regulatory Control
Model Predictive Control
Inferential, Sequential, and Compressor Control
By End-user Vertical
Oil and Gas
Petrochemical
Pharmaceutical
Food and Beverage
Energy and Power
Chemical
Other End-user Verticals
By Geography***
North America
United States
Canada
Europe
United Kingdom
Germany
France
Asia
China
India
Japan
Australia and New Zealand
Latin America
Middle East and Africa
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Advanced Process Control (APC) Market Research FAQs

The Advanced Process Control Market size is expected to reach USD 2.74 billion in 2024 and grow at a CAGR of 8.38% to reach USD 4.10 billion by 2029.

In 2024, the Advanced Process Control Market size is expected to reach USD 2.74 billion.

ABB Ltd., Emerson Electric Co., Honeywell International Inc., Aspen Technology Inc. and General Electric Co. are the major companies operating in the Advanced Process Control Market.

Asia Pacific is estimated to grow at the highest CAGR over the forecast period (2024-2029).

In 2024, the North America accounts for the largest market share in Advanced Process Control Market.

In 2023, the Advanced Process Control Market size was estimated at USD 2.51 billion. The report covers the Advanced Process Control Market historical market size for years: 2019, 2020, 2021, 2022 and 2023. The report also forecasts the Advanced Process Control Market size for years: 2024, 2025, 2026, 2027, 2028 and 2029.

Advanced Process Control Industry Report

Statistics for the 2024 Advanced Process Control market share, size and revenue growth rate, created by Mordor Intelligence™ Industry Reports. Advanced Process Control analysis includes a market forecast outlook to 2029 and historical overview. Get a sample of this industry analysis as a free report PDF download.

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Advanced Process Control Market Size & Share Analysis - Growth Trends & Forecasts (2024 - 2029)