Advanced Process Control Market Overview
The Advanced Process Control Market is projected to grow from USD 2.05 billion in 2024 to USD 4.25 billion by 2032, exhibiting a compound annual growth rate (CAGR) of 9.48% during the forecast period (2024 - 2032). Additionally, the market size for Advanced Process Control was valued at USD 1.88 billion in 2023. A growing need for energy-efficient processes and improved control software, an increase in the use of advanced process control technology in industrial processes, and the capacity of APC systems to enhance performance while lowering errors and downtime are the key market drivers enhancing the market growth.
Figure 1: Advanced Process Control (APC) Market Size, 2024 - 2032 (USD Billion)
Source: Secondary Research, Primary Research, Market Research Future Database and Analyst Review
Industry News of Advanced Process Control (APC) Market
February 2023- For edge controllers, Yokogawa Electric Corporation in fact has begun offering a reinforcement learning service. According to the needs of the end user, this autonomous control service for OpreX Realtime OS-based Machine Controllers (e-RT3 Plus) consists of packaged software, an optional consulting service, and/or a training program. It uses Factorial Kernel Dynamic Policy Programming reinforcement learning AI algorithm. While consultancy and the training program will be offered initially in Japan and thereafter in other regions, this software will be made available worldwide. PID control & advanced process control are examples of conventional control technology.
Sometimes modifications are necessary to achieve sophisticated control utilizing PID control or APC, and these adjustments might take a lot of time and work. Moreover, some plant processes must be regulated manually because they are not suited for PID control or APC. This necessitates that operators use discretion when entering the control inputs. For such circumstances, a new technology called autonomous control artificial intelligence (AI) achieves complicated control and does away with the necessity for manual operations.
Advanced Process Control (APC) Market Trends
Growing awareness regarding industry 4.0 is driving the market growth
Market CAGR for advanced process control (APC) is driven by the rapid implementation of industry 4.0. The digital supply chain across industries has changed due to Industry 4.0. Organizations are compelled to embrace industry 4.0 by customers' evolving needs, such as fast and personalized services. The market participants collaborate with tech-savvy businesses to provide novel solutions based on rapidly evolving technologies. For instance, Tech Mahindra Ltd and Honeywell International Inc. teamed together in February 2020 to create digital "Factories of the Future" using digital technology. The partnership intends to assist firms in hastening the process of digital transformation.
Similarly, Siemens and SAP SE worked together to provide businesses with industry 4.0-enabled business processes. These procedures will make it possible to create a digital thread that spans the entire product lifecycle. To help manufacturers scale up their growth and achieve the potential of industry 4.0 technologies and solutions, businesses are focused on using 5G, industry 4.0, digital transformation, and software capabilities.
Human mistake is always present in manual processes and human intervention to some degree, and when it comes to complicated industrial processes, the inaccuracy and miscalculation could be large, which can result in significant company loss. APC forecasts the accuracy of product estimates in addition to reducing the fault. Up to 90% of workplace accidents are caused by human mistakes, which can be expensive, waste time, and reduce productivity. In the United States, 5,190 fatal work injuries were reported in 2021, an 8.9% rise from 4,764 in 2020.
Automation is the only technology used in every country on earth and in which industries are willing to invest a lot of money. Additionally, offering remote process automation technologies lessens reliance on labor and addresses labor shortages. Thus, driving the advanced process control (APC) market revenue.
Advanced Process Control (APC) Market Segment Insights
Advanced Process Control (APC) Type Insights
The Advanced Process Control (APC) Market segmentation, based on type, includes advanced regulatory control, multivariable model predictive control, inferential control, sequential control and compressor control. Compressor control dominated the market in 2022. Expanding power generation and the developing petrochemical, metals & mining, oil & gas, and refining industries are the main drivers of the compressor control system. The use of compressor control systems in the oil and gas and petroleum industries is another element driving this market's growth.
November 2022 Northeast Compressor's operating assets have been acquired by Atlas Copco. Northeast Compressor serves a diverse spectrum of industrial customers in upstate New York, USA, by selling air compressors, related equipment, and services. The purchased company will be integrated into the Compressor Technology Business Area.
Additionally, in 2022, the multivariable model predictive control witnessed significant growth. The benefit of the MPC is that it is a multivariable controller that simultaneously controls the outputs while accounting for all interactions between the system variables.
Advanced Process Control (APC) Revenue Source Insights
The Advanced Process Control (APC) Market segmentation, based on revenue source, includes software and services. In 2022, the service sector held the highest market share. The demand for APC services is anticipated to increase significantly throughout the projected period because many deployed advanced process control systems are in developed nations like North America and Europe. The software segment is anticipated to develop at the greatest CAGR throughout the projection period. The software category comprises sophisticated platforms and applications for process control. Applications for sophisticated process control aid companies in streamlining operations and boosting output.
Advanced Process Control (APC) Application Insights
The Advanced Process Control (APC) Market data, based on application, includes oil & gas, pharmaceuticals, power, food & beverages, petrochemicals, chemicals and semiconductors. The oil and gas segment, which held the biggest market share in 2022, is anticipated to increase significantly over the next several years because APC systems are widely used in the industry. This is due to the complexity of processing processes in the oil and gas sector, which necessitate real-time regulation. In the APC market, energy and power type are anticipated to develop at a rapid CAGR.
These system applications may be created to reduce utility expenditures by as much as 60%. Boiler loads, gas turbine loads, and other aspects of energy production can all be optimized using the system.
Advanced Process Control (APC) Regional Insights
By Region, the study provides market insights into Asia-Pacific, North America, Europe, and Rest of the World. The North American advanced process control (APC) market area will dominate this market. It is anticipated that the construction of new power plants, major semiconductor manufacturing sectors, and the demand for industrial automation will enhance the North American APC systems. The nation also produces the most nuclear energy globally and has the biggest nuclear power installed capacity. 99 nuclear reactors across 31 states generate about 20% of the nation's electricity. By 2021, new nuclear reactors are predicted to have been developed.
The need for advanced process control systems in the area is rising significantly as they increase the reliability of nuclear power plants.
Further, the major countries studied in the market report are The U.S., Canada, German, France, UK, Italy, Spain, China, Japan, India, Australia, South Korea, and Brazil.
Europe advanced process control (APC) market accounts for the second-largest market share. APC systems are widely used in the region's chemical, pharmaceutical, pulp, paper, and oil and gas industries. Almost 1,700 German chemical businesses and German subsidiaries of foreign companies are represented by the German Chemical Industry Association (VCI). Further, the German advanced process control (APC) market held the major market share, and the UK advanced process control (APC) market was the fastest-growing market in the European region.
The Asia-Pacific Advanced Process Control (APC) Market is estimated to propel rapidly from 2023 to 2030. Expanding industries like paints and coatings, medicines, and chemicals in developing nations like China and India substantially impact the market's growth. The healthcare industry in China is fiercely competitive, with more than 4,000 pharmaceutical companies. Moreover, China’s advanced process control (APC) market held the largest market share, and the Indian advanced process control (APC) market was the fastest-growing market in the Asia-Pacific region.
Advanced Process Control (APC) Key Market Players & Competitive Insights
Leading market players are investing largely in research and development to expand their product lines, which will help the advanced process control (APC) market grow even more. Market participants are engaging in various strategic initiatives to increase their worldwide reach., with important market developments including new product launches, contractual agreements, mergers and acquisitions, higher investments, and collaboration with other organizations. To expand and survive in a more competitive and rising market climate, the advanced process control (APC) industry must offer cost-effective items.
Manufacturing locally to minimize operational costs is one of the key business tactics manufacturers use in the global advanced process control (APC) industry to benefit clients and increase the market sector. In recent years, the advanced process control (APC) industry has offered some of the most significant medicinal benefits. Major players in the advanced process control (APC) market, including Yokogawa Electric Corporation (Japan), Honeywell International (US), ABB Ltd (Switzerland), General Electric Company (US), and others, are attempting to increase market demand by investing in research and development operations.
ABB is a technology pioneer in electrification and automation, paving the way for a more sustainable and resource-efficient future. The company's solutions combine engineering know-how and software to maximize how objects are created, moved, powered, and operated. ABB's 105,000 workers are dedicated to driving innovations that accelerate industrial transformation, building on more than 130 years of excellence. In June 2021, ABB released the most recent version of its distributed control system. ABB has created a new addition to its flagship Extended Automation System 800xA that allows for simple design and implementation of APC in ABB's 800xA DCS: 800xA APC.
Yokogawa Electric Corporation is a Japanese multinational software and electrical engineering corporation that operates through measurement, control, and information technologies. Yokogawa is a world-class manufacturer of Industrial Automation and Test and Measurement solutions. Yokogawa delivers field-proven operating efficiency, safety, quality, and dependability by combining excellent technology with engineering services, project management, and maintenance. In June 2021, Yokogawa and Shell stated that they had developed Platform for Advanced Control and Estimation R5.03, published on June 2 as part of Yokogawa's OpreX asset operations and optimization family.
The platform is a software suite that combines Shell's superior plant process control technology with Yokogawa's real-time control technology to assist customers in enhancing productivity by increasing product output and lowering energy usage.
Key Companies in the advanced process control (APC) market include
- Emerson Electric Corporation (US)
- Rockwell Automation Inc. (US)
- Honeywell International (US)
- Yokogawa Electric Corporation (Japan)
- Aspen Technology Inc. (US)
- Rudolph Technologies Inc. (US)
Advanced Process Control Market Industry Developments
- Q2 2024: Aspen Technology Announces New Release of aspenONE® V14 Software to Accelerate Industrial Digital Transformation Aspen Technology launched aspenONE® V14, an updated suite of advanced process control and optimization software, introducing new AI-driven features to enhance industrial automation and process efficiency.
- Q2 2024: Yokogawa Launches OpreX™ Data Model Broker to Accelerate Digital Transformation in Process Industries Yokogawa introduced the OpreX™ Data Model Broker, a new software platform designed to facilitate advanced process control and data integration for process industries, supporting digital transformation initiatives.
- Q2 2024: Emerson Expands DeltaV™ Automation Platform with New Advanced Process Control Capabilities Emerson announced enhancements to its DeltaV™ automation platform, adding new advanced process control modules aimed at improving operational efficiency and process optimization for industrial customers.
- Q3 2024: Honeywell Launches Experion® PKS Release 520.1 with Enhanced Advanced Process Control Features Honeywell released Experion® PKS Release 520.1, which includes upgraded advanced process control functionalities to help process industries achieve higher reliability and performance.
- Q3 2024: ABB Launches ABB Ability™ Advanced Process Control Suite for Process Industries ABB introduced the ABB Ability™ Advanced Process Control Suite, a new software solution designed to optimize process performance and energy efficiency in industries such as chemicals, oil & gas, and mining.
- Q3 2024: Siemens Expands Xcelerator Portfolio with New Advanced Process Control Applications Siemens announced the addition of advanced process control applications to its Xcelerator portfolio, aiming to support digitalization and process optimization in manufacturing and process industries.
- Q4 2024: Rockwell Automation Introduces PlantPAx 5.1 with Advanced Process Control Enhancements Rockwell Automation launched PlantPAx 5.1, featuring new advanced process control capabilities to improve plant-wide process automation and operational agility.
- Q4 2024: Schneider Electric Unveils EcoStruxure™ Advanced Process Control for Sustainable Operations Schneider Electric announced EcoStruxure™ Advanced Process Control, a new solution designed to help industrial customers achieve sustainability goals through improved process efficiency and reduced energy consumption.
- Q1 2025: Aspen Technology and Microsoft Announce Strategic Partnership to Accelerate Industrial AI Adoption Aspen Technology and Microsoft formed a strategic partnership to integrate AspenTech’s advanced process control solutions with Microsoft Azure, aiming to accelerate AI adoption in process industries.
- Q1 2025: Yokogawa and Shell Renew Global Framework Agreement for Advanced Process Control Solutions Yokogawa and Shell renewed their global framework agreement, extending collaboration on the deployment of advanced process control and optimization solutions across Shell’s global operations.
- Q2 2025: Emerson Acquires Fluxa to Strengthen Advanced Process Control and Digital Transformation Offerings Emerson acquired Fluxa, a provider of process optimization software, to enhance its advanced process control and digital transformation portfolio for the process industries.
- Q2 2025: ABB and Tata Consultancy Services Announce Partnership to Deliver Advanced Process Control Solutions ABB and Tata Consultancy Services entered a partnership to jointly deliver advanced process control and digital solutions for industrial customers worldwide.
Advanced Process Control (APC) Market Segmentation
Advanced Process Control (APC) Type Outlook
- Advanced Regulatory Control
- Multivariable Model Predictive Control
- Sequential Control and Compressor Control
Advanced Process Control (APC) Revenue Source Outlook
Advanced Process Control (APC) Application Outlook
Advanced Process Control (APC) Regional Outlook
| Attribute/Metric |
Details |
| Market Size 2023 |
USD 1.88 billion |
| Market Size 2024 |
USD 2.05 billion |
| Market Size 2032 |
USD 4.25 billion |
| Compound Annual Growth Rate (CAGR) |
9.48% (2024-2032) |
| Base Year |
2023 |
| Market Forecast Period |
2024-2032 |
| Historical Data |
2019- 2021 |
| Market Forecast Units |
Value (USD Billion) |
| Report Coverage |
Revenue Forecast, Market Competitive Landscape, Growth Factors, and Trends |
| Segments Covered |
Type, Revenue Source. and Application |
| Geographies Covered |
Asia Pacific, North America, Europe, and the Rest of the World |
| Countries Covered |
The U.S., Canada, German, France, UK, Italy, Spain, China, Japan, India, Australia, South Korea, and Brazil |
| Key Companies Profiled |
Yokogawa Electric Corporation (Japan), Honeywell International (US), ABB Ltd (Switzerland), and General Electric Company (US). |
| Key Market Opportunities |
· Improving data accuracy can improve the performance of the overall system |
| Key Market Dynamics |
· Rising safety and security concerns are expected to boost the demand for APC systems |
Advanced Process Control Market Highlights:
Frequently Asked Questions (FAQ):
The size of the global market of advanced process control (APC) is prized at USD 1.88 Billion in 2023.
The global market is predicted to grow at a CAGR of 9.48% during the forecast period, 2024-2032.
North America had the major share of the global market.
The key players in the market are Yokogawa Electric Corporation (Japan), Honeywell International (US), ABB Ltd (Switzerland), and General Electric Company (US).
The compressor control type dominated the market in 2023.
The oil and gas sector had the largest share of the global market.
