Advanced Process Control Market

Market Definition

The market involves technologies and software that optimize industrial operations by predicting and adjusting process variables in real-time. It covers methods like predictive control, multivariable control, and inferential control techniques. These tools help improve production processes, increase efficiency, and maintain product quality.

Applications range from minimizing energy use to stabilizing complex systems where conventional controls are insufficient for consistent performance. The report covers key driving factors, industry trends, regional developments, and regulatory frameworks impacting market growth through the projection period.

Advanced Process Control Market Overview

The global advanced process control market size was valued at USD 2430.8 million in 2023 and is projected to grow from USD 2659.5 million in 2024 to USD 5094.2 million by 2031, exhibiting a CAGR of 9.73% during the forecast period.

The growth of the market is fueled by the rising adoption of Industrial IoT, enabling real-time data analysis and process optimization. Additionally, advancements in sensor technologies enhance the accuracy and efficiency of control systems. These factors are driving the demand for more sophisticated and integrated control solutions, thereby driving the fueling market growth.

Major companies operating in the advanced process control industry are Emerson Electric Co., Honeywell International Inc., ABB, Schneider Electric, Rockwell Automation, Inc., Yokogawa Electric Corporation, Siemens, General Electric, Aspen Technology, Inc., Mitsubishi Electric Corporation, Metso Oyj, Schlumberger Limited, KBC Advanced Technologies Ltd., Valmet Oyj, and MKS Instruments, Inc.

Industries are increasingly focusing on real-time process monitoring and predictive maintenance to reduce downtime and operational risks. Advanced process control systems integrate analytics and predictive algorithms that foresee process deviations before they impact production.

This proactive approach reduces maintenance costs and extends equipment life. The shift towards data-driven operations is prompting companies across sectors to adopt APC solutions, in turn fueling the growth of the market.

• ​In March 2025, Valmet introduced the Valmet High Yield Pulping Optimizer, the world's first advanced process control (APC) system specifically designed for optimizing high-yield pulping processes in the pulp and paper industry. This innovative solution integrates automated controls for cooking and refining, enabling mills to maximize pulping output while reducing costs and stabilizing product quality.

Key Highlights

1. The advanced process control industry size was valued at USD 2430.8 million in 2023.
2. The market is projected to grow at a CAGR of 9.73% from 2024 to 2031.
3. North America held a market share of 33.24% in 2023, with a valuation of USD 808.1 million.
4. The software segment garnered USD 917.3 million in revenue in 2023.
5. The chemicals segment is expected to reach USD 1136.5 million by 2031.
6. Asia Pacific is anticipated to grow at a CAGR of 10.75% during the forecast period.

Market Driver

"Rising Adoption of Industrial IoT"

The growing integration of Industrial Internet of Things (IIoT) technologies is facilitating greater deployment of APC solutions. IIoT enables real-time data acquisition, advanced analytics, and remote monitoring, critical for effective process control.

APC systems benefit from IIoT by gaining better visibility and predictive insights into production environments, allowing for faster response to process variations, improved operational efficiency, and reduced downtime. This is accelerating the growth of advanced process control market across industries focused on boosting productivity and system reliability.

• ​In March 2024, Yokogawa Electric Corporation launched the OpreX Robot Management Core, a software designed to integrate and manage various mobile robots to perform plant maintenance tasks. This solution aims to enhance safety and efficiency in manufacturing operations by enabling unified control of different robot types for autonomous plant operations.

Market Challenge

"Integration Complexity"

A significant challenge for the growth of the advanced process control market is the complexity of integrating APC systems with existing infrastructure. Many companies face difficulties in seamlessly connecting new technologies to legacy systems, which leads to high initial costs and extended downtimes during installation.

To address this, key players are adopting flexible, scalable APC solutions that can be easily integrated into existing operations. They are also investing in advanced training and support services to ensure smooth implementation and minimize disruptions. Additionally, developing modular solutions allows for gradual system upgrades, making the transition more manageable for businesses.

Market Trend

"Advancements in Sensor Technologies"

The development of advanced and reliable sensors is enhancing the capabilities of advanced process control systems. Sensors that provide real-time data on variables like temperature, pressure, and flow are critical to maintaining optimal operational conditions.

The continuous improvement in sensor technology allows for more accurate process control, enabling better performance and reliability across industries. This trend is helping expand the advanced process control market as companies look to improve precision in their operations.

• In November 2024, Allegro MicroSystems introduced its new inductive position sensors, the A17802 and A17803, at Electronica 2024. These sensors provide high-resolution position sensing with integrated diagnostics, offering a compact and economical alternative to traditional resolvers and encoders. They are designed for applications in motor position sensing, including traction motors in electric vehicles and servo motors in industrial automation and robotics.

Advanced Process Control Market Report Snapshot

Market Segmentation

• By Component (Hardware, Software, Services): The Software segment earned USD 917.3 million in 2023 due to its ability to offer flexible, scalable solutions that enable real-time data analysis, process optimization, and seamless integration with existing systems.
• By End-use Industry (Chemicals, Food & Beverages, Energy & Power, Paper & Pulp, Mining, Pharmaceuticals, Oil & Gas, Others): The Chemicals segment held 22.42% of the market in 2023, due to its high demand for process optimization, efficiency, and safety, which are critical in complex chemical production processes requiring precise control and real-time monitoring.

Advanced Process Control Market Regional Analysis

Based on region, the market has been classified into North America, Europe, Asia Pacific, Middle East & Africa, and South America.

The North America advanced process control market share stood around 33.24% in 2023 in the global market, with a valuation of USD 808.1 million. The push towards smart manufacturing and Industry 4.0 in North America significantly driving the growth of the market.

• In February 2025, Siemens announced a USD 285 million investment in U.S. manufacturing, including the establishment of new facilities in California and Texas. This investment is part of Siemens' strategy to enhance manufacturing capabilities and integrate AI advancements into their operations. The new facilities will produce electrical products supporting various U.S. sectors and power AI data centers, contributing to Siemens' total investment of over USD 100 billion in the U.S. over the past 20 years.

Moreover, the region is home to a strong industrial base, including sectors like oil and gas, chemicals, pharmaceuticals, and power generation. As industries look for ways to increase productivity and reduce operational costs, the market in the region is witnessing consistent growth. This industrial diversity provides a strong foundation for the adoption of APC technology, in turn driving the growth of the market in this region.

Asia Pacific advanced process control industry is poised for significant growth at a robust CAGR of 10.75% over the forecast period. Asia Pacific is experiencing rapid industrialization and urbanization, especially in emerging economies.

As industries grow, they require more efficient and automated systems to meet rising production demands. This shift toward advanced manufacturing processes is driving the demand for APC technologies across various sectors like automotive, and consumer goods in the region.

Furthermore, Asia Pacific has a large and expanding chemical and petrochemical sector, which is a key driver for the growth of the market. The ongoing expansion and modernization of these industries in the region are boosting demand for APC solutions.

Regulatory Frameworks

• In the U.S., the Bureau of Industry and Security (BIS) enforces export controls on advanced computing technologies impacting APC systems, particularly in semiconductor industries. The Nuclear Regulatory Commission (NRC) governs the use of APC in nuclear facilities, ensuring compliance with safety standards for emerging technologies like small modular reactors.
• In the European Union, the General Data Protection Regulation (GDPR) impacts APC systems that process personal data, ensuring privacy and data protection. Meanwhile, the VDI/VDE 2191 standard in Germany provides guidelines for implementing APC systems, focusing on predictive control, safety, and process optimization within various industrial sectors.
• China's National Development and Reform Commission (NDRC) oversees the development and implementation of APC technologies, promoting advancements in key industries. The State Administration for Market Regulation (SAMR) ensures that APC systems meet safety, quality, and performance standards, facilitating both domestic use and export compliance.
• South Korea’s industrial technologies, including APC systems, are protected under the Act on Prevention of Divulgence and Protection of Industrial Technology. The Korean Agency for Technology and Standards (KATS) develops and enforces standards for APC systems, ensuring their reliability, safety, and conformity to national regulations in various industries.

Competitive Landscape

Market players in the advanced process control industry are increasingly adopting strategies like developing new products and expanding their product lines. These efforts are crucial for staying competitive and meeting the growing demand for innovative solutions.

By enhancing their product offerings, companies are able to address diverse customer needs, improve efficiency, and ensure better integration with existing systems.

• In August 2024, Yokogawa launched the OpreX Open Automation SI Kit and the OpreX OPC UA Management Package. These products play important roles in the implementation of Open Process Automation systems, enhancing the company's OpreX Control and Safety lineup.

List of Key Companies in Advanced Process Control Market:

• Emerson Electric Co.
• Honeywell International Inc.
• ABB
• Schneider Electric
• Rockwell Automation, Inc.
• Yokogawa Electric Corporation
• Siemens
• General Electric
• Aspen Technology, Inc.
• Mitsubishi Electric Corporation
• Metso Oyj
• Schlumberger Limited.
• KBC Advanced Technologies Ltd.
• Valmet Oyj.
• MKS Instruments, Inc.

Recent Developments (Product Launch/Partnerships/Agreements)

• In March 2025, Emerson expanded its DeltaV Automation Platform with the release of the DeltaV version 15 Feature Pack 3 update for its distributed control system. This update introduces new features designed to assist modern process manufacturers in addressing both current and future industry challenges.
• In February 2025, Emerson partnered with HPCL-Mittal Energy Limited (HMEL), a prominent petrochemical and refining company in India, to optimize operations across HMEL's refining, petrochemicals, and sustainable fuels complex. The collaboration will implement AspenTech’s multi-unit dynamic optimization solutions to enhance margins and meet sustainability targets. This will be achieved by integrating planning, scheduling, and advanced process control in a closed-loop system, along with end-to-end demand forecasting, planning, and scheduling across the oil-to-chemical value chain.
• In May 2024, ABB was awarded a contract by Södra Cell to implement optimization control, aimed at helping Sweden's largest forest-owner association and leading pulp producer achieve higher efficiency levels. As part of the agreement, ABB will enhance the ABB Ability System 800xA distributed control system (DCS) by integrating advanced process control (APC) into the bleaching process at the Södra Cell mill in Värö.