Global Market Size, Forecast, and Trend Highlights Over 2025-2037
PC-based Automation Market size was valued at USD 32.5 billion in 2024 and is projected to reach USD 55.3 billion by the end of 2037, rising at a CAGR of 4.2% during the forecast period, i.e., 2025-2037. In 2025, the industry size of PC-based automation is assessed at USD 33.8 billion.
The primary driver of the market is the rising adoption of Industry 4.0 and smart manufacturing technologies. The shift toward Industry 4.0 and smart factories is fueling the demand for intelligent, connected automation systems. The PC-based automation supports real-time data analytics, remote monitoring, and seamless integration with industrial IoT devices. For instance, a recent development in the realm of Industry 4.0 and smart manufacturing is Nielsoft’s launch of comprehensive Industry 4.0 solutions in India in August 2024. These solutions aim to accelerate digital transformation in manufacturing and automation by providing manufacturing and building automation and digital factory solutions at the shop floor, factory, and enterprise levels.
Moreover, the demand for highly adaptive automation solutions in the automotive, electronics, food & beverage, and pharmaceutical industries is accelerating the adoption of PC-based automation systems as part of the Industry 4.0 revolution. As manufacturers seek greater efficiency, cost-effectiveness, and sustainability, PC-based automation continues to be a key factor in smart manufacturing. PC-based automation reduces hardware costs by consolidating multiple control functions into a single system. High-speed processors enable faster computations, better automation control, and improved system reliability.
PC-based Automation Sector: Growth Drivers and Challenges
Growth Drivers
- Advancements in AI and ML: AI-driven automation enhances predictive maintenance, process optimization, and adaptive control in industries. Machine learning allows real-time decision-making, improving efficiency and reducing downtime. For instance, in March 2024, Rockwell Automation introduced a new software, FactoryTalk Analytics Guardian AI, that provides insights on predictive maintenance via continuous condition-based monitoring. The software helps maintenance engineers track the right information at the proper time to optimize maintenance activities and reduce unplanned downtime.
- Increasing demand for industrial efficiency and flexibility: Industries need high-performance, flexible, and cost-effective automation solutions. A recent development exemplifying the increasing demand for industrial efficiency and flexibility through PC-based automation is Beckhoff Automation’s TwinCAT automation software program. This platform enables seamless integration of machine learning, vision edge computing and cloud connectivity, opening new opportunities for automation applications. It combines IT and OT technologies, allowing for code development, building, and debugging without the need for hardware thereby enhancing scalability and flexibility in industrial automation. PC-based automation offers better scalability, software-driven upgrades, and open system architecture compared to traditional PLCs.
Challenges
- High initial investment and implementation cost: Setting up a PC-based automation system requires significant capital investment in hardware, software, and integration with existing industrial systems. Small and medium enterprises often find it challenging to justify the upfront costs despite long-term benefits.
- Cybersecurity risks and data vulnerability: As PC-based automation systems rely on IoT, cloud computing, and remote monitoring, they become more vulnerable to cyberattacks, hacking, and data breaches. Industries must invest in advanced cybersecurity solutions to protect sensitive operational data.
PC-based Automation Market: Key Insights
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Base Year |
2024 |
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Forecast Year |
2025-2037 |
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CAGR |
4.2% |
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Base Year Market Size (2024) |
USD 32.5 billion |
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Forecast Year Market Size (2037) |
USD 55.3 billion |
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Regional Scope |
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PC-based Automation Segmentation
Application (Process Automation, Discrete Automation, Building Automation, Manufacturing Automation)
Process automation segment is likely to capture PC-based automation market share of over 32.4% by 2037. Process automation in the PC-based automation market is transforming industries by enhancing efficiency, accuracy, and scalability through software-driven control systems. Unlike traditional PLC-based automation, PC-based solutions provide greater flexibility, real-time data processing AI, IoT, and cloud computing integration. Industries such as manufacturing, pharmaceuticals, oil & gas, and food processing leverage PC-based automation for monitoring tasks, production lines, predictive maintenance, quality control, and supply chain optimization. For instance, in January 2024, ABB introduced a new automation solution for the cold block stage of beer production to improve efficiency and optimization. The ABB Ability BeerMaker system is designed for breweries to enhance safety, quality, and productivity. It ensures better connectivity across the brewing process, promoting sustainable water and energy use.
These systems enable seamless communication between machines, remote monitoring, and adaptive control allowing businesses to reduce downtime, improve product consistency, and lower operational costs. As the demand for smart factories and Industry 4.0 solutions grows, PC-based process automation drives higher productivity, data-driven decision-making, and enhanced system reliability across industrial applications.
System Type (Programmable Logic Controller, Supervisory Control and Data Acquisition, Distributed Control System)
The programmable logic controller is expected to hold a significant PC-based automation market share through 2037. Programmable logic controllers (PLCs) serve as a reliable controller for real-time industrial processes. While traditional PLCs are stand-alone systems designed for deterministic control, modern PC-based automation integrates PLC functionality with industrial PCs, allowing for enhanced flexibility, scalability, and data processing. For instance, in 2024, Ckylop, a leader in packaging automation, revolutionized its operations by integrating PLCs with PC-based systems. This integration enhanced flexibility and data processing capabilities by using AI-driven analytics and cloud integration.
Our in-depth analysis of the global PC-based automation market includes the following segments:
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Application |
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System Type |
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End use |
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Component |
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Customize this ReportPC-based Automation Industry - Regional Scope
North America Market Analysis
North America in PC-based automation market is set to capture over 32.7% revenue share by 2037, due to the increasing adoption of Industry 4.0 and smart manufacturing. AI, IoT, and cloud integration are driving demand for advanced automation solutions in industries such as automotive, healthcare, and energy. Leading companies such as Rockwell Automation, Siemens, and Beckhoff are expanding their presence in the region. Moreover, government initiatives and investments in industrial automation and digital transformation are fueling market growth.
The PC-based automation market in the U.S. is fueled by the rising need for high-performance, software-driven industrial control systems. The country’s focus on manufacturing automation, robotics, and AI-powered analytics is accelerating adoption across various sectors. Tech giants and industrial automation leaders are investing heavily in innovation and R&D to enhance automation capabilities. In 2024, OnLogic, a U.S.-based industrial PC manufacturer, expanded its operations by opening a new 160,000 sq. ft. global headquarters in South Burlington, Vermont. This expansion reflects the increasing demand for PC-based automation systems in the U.S industrial sector.
The PC-based automation market in Canada is expanding due to the country’s emphasis on smart factories and energy-efficient industrial solutions. Strong investments in AI-driven automation and industrial IoT are transforming the manufacturing and logistics sectors. The rise of automation startups and collaborations with global tech firms is accelerating innovation. For instance, in June 2024, Cyklop International, a leading supplier of systems for securing products, acquired Polaris Systems Inc. for packaging solutions.
Europe Market Analysis
Europe is anticipated to report a significant PC-based automation market share through 2037, driven by the region’s focus on advanced manufacturing, robotics, and digital twin technology. Strict regulations on energy efficiency and sustainability are pushing industries towards smart automation solutions. Leading firms in Europe such as Siemens, Schneider Electric, and Bosch are pioneering innovations in industrial automation. The rapid adoption of 5G and edge computing is further expected to enhance automation capabilities across various sectors.
The PC-based automation market in Germany is thriving due to the country’s leadership in precision engineering and industrial digitalization. The strong presence of automotive and machinery manufacturing industries is accelerating the adoption of advanced automation. Additionally, Germany’s Industry 4.0 initiative is driving innovation in AI-powered, software-driven automation. Top companies such as Siemens, Beckhoff, and Festo are developing next-generation automation solutions for smart factories.
The PC-based automation market in the UK is expanding due to the rising adoption of AI-driven robotics and smart manufacturing solutions. The country’s strong focus on digital transformation in industries such as pharmaceuticals, aerospace, and food processing is driving demand. Moreover, government-backed initiatives and investments in automation R&D are accelerating technological advancements.
Companies Dominating the PC-based Automation Landscape
- Siemens
- Company Overview
- Business Strategy
- Key Product Offerings
- Financial Performance
- Key Performance Indicators
- Risk Analysis
- Recent Development
- Regional Presence
- SWOT Analysis
- Bosch Rexroth
- Rockwell Automation
- Advantech
- Schneider Electric
- ABB
- Yokogawa Electric
- Emerson
- National Instruments
- Phoenix Contact
- Honeywell
- TE Connectivity
- Cognex
The PC-based automation market is led by several key players driving industrial innovation and digital transformation. Siemens dominates with its SIMATIC Industrial PCs and Xcelerator platforms enabling smart automation. Beckhoff Automation specializes in PC based control systems involving technologies like TwinCAT software for real-time automation. Rockwell Automation integrates industrial PCs with IoT and AI enhancing efficiency in manufacturing and process industries. Schneider Electric leads in sustainable automation with its EcoStruxure platform optimizing energy and industrial operations. Here are some leading players in the PC-based automation market:
In the News
- In February 2025, Ranpak partnered with Rabot to expand AI-driven packaging solutions. Rabot’s vision AI platform provides real-time visibility and insights through video recordings and AI models during packing, return, inbound, and other operations.
- In January 2025, Addverb Technologies deployed many robotics-based production systems in companies to automate their manufacturing systems in the pharmaceuticals, consumer goods, and automotive sectors. The assembly lines in industries adopt flexible robotics to meet rising consumer expectations.
- In November 2024, Rockwell Automation, Inc., the world’s largest industrial automation and digital transformation company, introduced FactoryTalk Vision AI, an inspection solution that uses AI and ML to enhance quality control in manufacturing.
Author Credits: Abhishek Verma
- Report ID: 7249
- Published Date: Mar 03, 2025
- Report Format: PDF, PPT
