Micro Programmable Logic Controller (Plc) Market Analysis APAC, North America, Europe, South America, Middle East and Africa - US, China, Japan, Germany, UK - Size and Forecast 2024-2028

Micro Programmable Logic Controller (PLC) Market Size 2024-2028 

The micro programmable logic controller (PLC) market size is estimated to grow by USD 2.37 billion at a CAGR of 7.08% between 2023 and 2028. The market is experiencing significant growth, driven by several key factors. Firstly, the increasing demand for compact automation solutions in various industries, particularly in small and medium-sized enterprises (SMEs), is fueling market expansion. Secondly, the expanding capabilities of micro PLCs, such as advanced connectivity options, increased processing power, and support for various communication protocols, are making them an attractive choice for automation applications. However, growing cybersecurity concerns are also posing challenges to the market, as micro PLCs are increasingly being targeted by cybercriminals. Manufacturers are responding by developing more robust security features, such as firewalls, encryption, and secure boot options, to protect against cyber threats. Overall, the market for micro PLCs is expected to continue growing, driven by these factors and the ongoing trend towards automation in various industries.

What will be the Size of the Market During the Forecast Period?

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Market Dynamics and Customer Landscape

The market encompasses a range of advanced automation solutions designed for industrial purposes. Micro PLCs are compact controllers that offer functionality similar to traditional PLCs but are smaller in size. They include variants such as Nano PLCs and Modular PLCs. Micro PLCs find extensive applications in various sectors like Automotives, Technology sector, Steel industry, Power industry, Oil & gas sector, and Energy sector, among others. The integration of Micro PLCs with advanced technologies such as Artificial intelligence and Internet of Things is driving their adoption. The market is segmented based on the hardware segment, which includes Micro PLCs, Nano PLCs, and Modular PLCs. The Automotive sector and Industrial automation are the major end-users of Micro PLCs. The Human Machine Interface (HMI) is an essential component of Micro PLCs, enabling easy operation and monitoring of industrial processes. Miniaturization is a significant trend in the Micro PLC market, with manufacturers focusing on developing smaller and more efficient controllers. The global Micro PLC market is expected to grow significantly due to the increasing demand for automation in various industries. Our researchers analyzed the data with 2023 as the base year, along with the key drivers, trends, and challenges. A holistic analysis of drivers will help companies refine their marketing strategies to gain a competitive advantage.

Key Market Driver

The increasing demand for compact automation solutions is notably driving market growth. In the realm of industrial automation, Programmable Logic Controllers (PLCs), including Micro PLCs and Nano PLCs, continue to play a pivotal role in various sectors such as Oil and Gas, Power, and the Technology sector. These controllers, available in Fixed, Modular designs, facilitate the automation of industrial processes in industries like Steel, Power, Food and Beverages, and the Automotive sector. With the emergence of Industry 4.0, also known as the IIoT, there is a growing need for advanced programming tools, simulation capabilities, and miniaturization for PLCs. This technology revolution brings benefits such as real-time communication, reliability, and energy efficiency. However, it also presents challenges in terms of cost reduction and the integration of benefits like predictive analytics and smart maintenance for manufacturers and system integrators. PLCs are instrumental in managing industrial automation processes at the control level, alongside the field level and operator level. They are indispensable in applications such as motion control, redundancy software, and robotics. In the context of the Power industry, PLCs ensure the efficient operation of assembly lines, industrial robots, and other machinery. In the Oil & Gas sector, they are used to manage drilling operations and production processes. The Energy sector benefits from their role in managing energy-efficient solutions and edge computing. In the realm of home automation, PLCs are increasingly being used to manage various systems, further expanding their applications. The Hardware segment of PLCs includes Input devices, while the Services and Software segments cater to programming tools, simulation, and human-machine interface design. As technology advances, PLCs will continue to be a crucial component of industrial automation, with the integration of artificial intelligence and IoT-connected devices. Thus, such factors are driving the growth of the market during the forecast period.

Significant Market Trends

The expanding capabilities of micro PLCs is the key trend in the market. Micro Programmable Logic Controllers (PLCs), including Nano PLCs, have gained significant traction in the process and discrete industries for controlling standalone machinery. Micro PLCs offer several advantages over traditional PLCs, such as programming flexibility, ease of use, and communication capabilities, all within a compact structure. Initially designed for small machinery with basic serial communication, micro PLCs have evolved to support high-speed communication capabilities, larger program memory, and the ability to control large machines and multiple communication protocols. These advancements have expanded the applications of micro PLCs in various industrial sectors, including Oil and Gas, Power, and the Technology sector. In the Oil & Gas sector, micro PLCs are used for controlling valves, pumps, and compressors. In the Power industry, they are employed for power distribution and generation applications. In the Food and Beverages sector, micro PLCs are utilized in assembly lines and robotics. Micro PLCs are also finding extensive use in the Automotive sector for motion control and human-machine interface applications. The Hardware segment of the Industrial Automation market is witnessing growth due to the increasing adoption of micro PLCs, which offer energy-efficient solutions and are IoT-connected, enabling edge computing and integration with Artificial Intelligence and IIoT technologies. Moreover, redundancy software and simulation tools have been developed for micro PLCs, enhancing their capabilities for industrial purposes. Miniaturization and the integration of input devices have further expanded their applications, making micro PLCs an essential component of modern industrial processes. Thus, such trends will shape the growth of the market during the forecast period.

Major Market Challenge

The growing cybersecurity concerns is the major challenge that affects the growth of the market. Micro Programmable Logic Controllers (PLCs), including Nano PLCs, play a pivotal role in industrial automation by enhancing productivity and streamlining processes in sectors such as oil and gas, power, and the automotive industry. These systems enable the integration of advanced technologies like artificial intelligence, Internet of Things (IoT), and edge computing for motion control, simulation, and human-machine interface. However, the increasing use of PLCs in industrial processes also raises concerns regarding cybersecurity. Critical infrastructure sectors, such as oil and gas, power, and water and wastewater, are particularly vulnerable to cyberattacks, with potential consequences including operational failure and unethical data usage. Cybersecurity measures, such as redundancy software and programming tools, are essential to mitigate these risks and safeguard industrial processes. The hardware segment, including input devices and miniaturized PLCs like Nano PLCs, plays a crucial role in the implementation of these security solutions. In the context of the energy sector, energy-efficient solutions and the integration of IoT-connected devices are driving the demand for advanced PLCs. Additionally, industries like steel and food and beverages also benefit from the implementation of industrial automation using PLCs. Hence, the above factors will impede the growth of the market during the forecast period.

Exclusive Customer Landscape

The market forecasting report includes the adoption lifecycle of the market, covering from the innovator’s stage to the laggard’s stage. It focuses on adoption rates in different regions based on penetration. Furthermore, the report also includes key purchase criteria and drivers of price sensitivity to help companies evaluate and develop their market growth analysis strategies.

 Customer Landscape

Key Companies & Market Insights

Companies are implementing various strategies, such as strategic alliances, partnerships, mergers and acquisitions, geographical expansion, and product/service launches, to enhance their presence in the market.

ABB Ltd. - The company offers micro programmable logic controllers such as AC500 eCo, AC500 S, and AC500 XC.

The market research and growth report also includes detailed analyses of the competitive landscape of the market and information about key companies, including:

• ABB Ltd.
• Advantech Co. Ltd.
• Beckhoff Automation
• Beijer Electronics Group AB
• Eaton Corp. PLC
• Festo SE and Co. KG
• Fuji Electric Co. Ltd.
• Hitachi Ltd.
• Honeywell International Inc.
• IDEC Corp.
• Lenze SE
• Mitsubishi Electric Corp.
• OMRON Corp.
• Parker Hannifin Corp.
• Robert Bosch Stiftung GmbH
• Rockwell Automation Inc.
• Schneider Electric SE
• Siemens AG
• Toshiba Corp.
• Yaskawa Electric Corp.

Qualitative and quantitative analysis of companies has been conducted to help clients understand the wider business environment as well as the strengths and weaknesses of key market players. Data is qualitatively analyzed to categorize companies as pure play, category-focused, industry-focused, and diversified; it is quantitatively analyzed to categorize companies as dominant, leading, strong, tentative, and weak.

Market Segmentation

By End-user 

The automotive industry segment is estimated to witness significant growth during the forecast period. The market encompasses various types of controllers, including Micro PLCs and Nano PLCs, which are increasingly being adopted in diverse industries for automating industrial processes.

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The automotive industry segment accounted for USD 1.05 billion in 2018. Micro PLCs, known for their compact size and high processing power, are extensively used in sectors like Oil and Gas, Power, and the Automotive industry. These controllers serve as a crucial intermediary in the manufacturing process, facilitating communication between various stages such as design, analysis, inventory management, and distribution. In the Oil and Gas sector, Micro PLCs are utilized for controlling drilling operations, pipeline management, and refinery processes. In the Power industry, they are employed for managing power generation, transmission, and distribution. The Food and Beverages sector uses Micro PLCs for automating production lines, ensuring consistent product quality, and maintaining optimal temperature and humidity levels. Micro PLCs are also gaining popularity in the Industrial automation sector, particularly in the context of Industry 4.0 and the Internet of Things (IoT).

Regional Analysis

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APAC is estimated to contribute 38% to the growth of the global market during the market forecast period. Technavio’s analysts have elaborately explained the regional trends and drivers that shape the market during the forecast period.

The market encompasses a wide range of applications, including building automation, engine control, transmission control, fuel injection, lighting systems, HVAC systems, and security systems. In building automation, PLCs are utilized to manage and monitor various functions such as temperature, lighting, and ventilation. For engine control, they are employed to optimize fuel consumption and improve performance. In the realm of transmission control, PLCs ensure smooth gear shifting and efficient power transfer. In the case of fuel injection, these controllers regulate the quantity and timing of fuel delivery to the engine. Similarly, in lighting systems, they manage the power and sequence of lights, while in HVAC systems, they control temperature, humidity, and ventilation. Lastly, in security systems, PLCs monitor access control and alarm systems. The offering segment of the PLC market includes hardware, software, and services.

Segment Overview

The market report provides comprehensive data (region-wise segment analysis), with forecasts and estimates in "USD million " for the period 2024-2028, as well as historical data from 2018-2022 for the following segments.

• End-user Outlook
  • Automotive industry
  • Oil and gas industry
  • Power industry
  • Food and beverage industry
  • Others

• Product Outlook
  • Hardware
  • Software
  • Services

• Region Outlook
  • North America
    • The U.S.
    • Canada
  • Europe
    • U.K.
    • Germany
    • France
    • Rest of Europe
  • APAC
    • China
    • India
  • Middle East & Africa
    • Saudi Arabia
    • South Africa
    • Rest of the Middle East & Africa
  • South America
    • Argentina
    • Brazil
    • Chile

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Market Analyst Overview

Programmable logic controllers (PLCs) are essential components in industrial automation for managing and controlling various processes in diverse industries. Micro PLCs and Nano PLCs, smaller versions of traditional PLCs, are gaining popularity due to their compact size and low power consumption. Fixed PLCs and Modular PLCs cater to larger installations and offer flexibility in system configuration. Industries like Oil and Gas, Power, and Steel are significant consumers of PLCs for process control and optimization. Programming tools, simulation, motion control, redundancy software, robotics, input devices, and assembly lines are integral parts of PLC applications. The Technology sector, Automotive, and Industrial purposes are major markets for PLCs. Artificial intelligence and Internet of Things (IoT) are transforming PLCs with advanced capabilities like edge computing, energy-efficient solutions, and IIoT-connected devices. Hardware, Services, and Software segments cater to different aspects of PLC applications. The Automotive sector, Oil & gas sector, Energy sector, and Industrial automation are key end-users. Human machine interface, miniaturization, industrial processes, and IIoT are emerging trends in PLC market. In conclusion, PLCs play a crucial role in managing industrial processes across various sectors, from manufacturing to power generation. With advancements in technology, PLCs are becoming more efficient, versatile, and connected, offering new opportunities for growth and innovation.

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What are the Key Data Covered in this Market Research Report?

• CAGR of the market during the forecast period
• Detailed information on factors that will drive the market growth and forecasting between 2024 and 2028
• Precise estimation of the size of the market  and its contribution of the market in focus to the parent market
• Accurate predictions about upcoming market growth and trends and changes in consumer behaviour
• Growth of the market across APAC, North America, Europe, South America, and Middle East and Africa
• Thorough analysis of the market’s competitive landscape and detailed information about companies
• Comprehensive analysis of factors that will challenge the growth of market companies