Global Open Process Automation Systems Market Size Likely to Grow at a CAGR of 8.5% By 2035

Market Size and Growth

The market size of the Open Process Automation Systems is estimated to grow to USD 6.92 billion by 2026 and is intended to grow to USD 14.46 billion in the year 2035 at a CAGR of 8.5% in the 2026-2035 forecast period.

Open Process Automation Systems Market Revenue and Trends

The Open Process Automation Systems Market is an international industry that deals with open and interoperable automation systems, which enhance efficiency and flexibility in process industries including oil and gas, chemicals, power production, pharmaceuticals, and manufacturing. This is expanding the market because of the increased imperative to modernize legacy control environments, eliminate vendor lock-in, and enable smooth interoperability across multi-vendor automation environments. Market expansion is also being increased by the increasing use of industrial IoT, AI-based automation, and Industry 4.0 technologies. Indicatively, in June 2023, Schneider Electric increased its EcoStruxure Automation Expert, which is a software-defined platform that is utilized to accomplish open and scalable process automation environments. The digital manufacturing and industrial automation are being sustained, which will aid market growth in the long term.

Which are the Factors which have a considerable Impact on the Open Process Automation Systems Market Development?

The Open Process Automation Systems Market is expanding following the increasing necessity to modernize the old industrial control systems and decrease vendor lock-in. Open automation architectures enable industries to combine with a multi-vendor hardware and software system to enhance operational effectiveness and system adaptability. The open process automation solutions are taking over as industries concentrate on scalable and interoperable automation systems. Indicatively, in June 2023, Schneider Electric enriched its EcoStruxure Automation Expert system to help in open and software-defined industrial automation systems.

The other significant contributor to growth is the overwhelming usage of Industry 4.0 technologies, including industrial IoT, AI, and advanced analytics. The technologies allow real-time monitoring, predictive maintenance, and better optimization of processes in the industries. In line with this trend, in October 2024, ABB launched new AI-enabled features in its industrial automation systems to enhance the efficiency of industrial processes and the performance of the system.

Segment Insight

By Component

The hardware division of the Open Process Automation Systems Market presents the most successful market, as without physical systems like industrial controllers, sensors, edge computing systems, and networking devices being a part of the automation infrastructure, there are no automation systems. They serve to monitor and control as well as communicate processes in an industrial plant in real time. The software industry is experiencing an upswing because the industry is transforming into more analytical systems, automation tools that are AI-controlled, and computer-assisted software to enhance their operations and decision-making processes. Meanwhile, the services, such as system integration, installation, training, and technical assistance, are also increasing since the companies need special knowledge to be capable of implementing and supporting open automation systems. Schneider Electric, as an example, made the EcoStruxure Automation Expert platform in June 2023 to allow open and software-defined industrial automation systems.

By Deployment Type

On-premises solution is large in terms of deployment because most industrial operators prefer the concept of a system of control that is localized to be more reliable and secure and to deliver the goals of regulatory compliance. On-premises systems also enable industries to directly run sensitive information of operation and automation systems. Nevertheless, application of clouds is growing by an unusually high rate as businesses are implementing remote monitoring, scalable automation systems, and centralized data management systems to simplify the digital transformation project. A case in point is that in September 2023, Rockwell Automation launched new digital automation systems that will enhance the dialogue between the industrial equipment and the cloud-based analytics systems.

By Architecture

The market also needs the open distributed control systems (DCS) because they enhance the flexibility and interoperability of automation conditions whereby various vendors’ equipment and software can be easily interchangeable. The systems aid in the modernization of the old infrastructure that exists in the companies but without an in-depth automation system. The modular control systems are also on the increase since they enable industries to add value or replace the parts progressively, therefore reducing the cost and also increasing the size of the system. Moreover, the popularity of the interoperable automation solutions has also grown as the industries are more oriented toward the development of open ecosystems with the aim of enhancing the development of industrial connectivity. In March 2024 Emerson said it would make improvements to its DeltaV distributed control system to make it open and interoperable automation.

By Industry Vertical

One of the largest segments of industries is the oil and gas industry, since it constitutes a huge percentage proportion of the use of superior automation methods to carry out the complicated processes involved in exploration, refining, and production. The other important adopter is the chemical and power generation industry, which demands assured automation so as to control the scale of the processes as well as the effectiveness of the operations. In the meantime, pharmaceutical and manufacturing markets are gradually becoming open users of automation systems and hoping to aid in the areas of smart manufacturing, compliance, and optimization of production. In October 2024, ABB announced new industrial automation capabilities that are based on AI and aimed to enhance the performance of the processes in the industries.

By Application

Regarding the sphere of application, process control takes the leading place in the market, as the sphere of application of automation systems is large to control and regulate the processes in the industry in real time, to regulate the quality of the created products, and to guarantee the balance of activities. The other is the expansion in asset management solutions, where the industries make efforts to enhance equipment performance by use of predictive maintenance solutions and digital monitoring solutions. Also, it is becoming the norm to use plant optimization and industrial monitoring systems as companies try to drag organizational output and minimize downtime in the intricate nature of the production processes. One such example is that Siemens unveiled novel digital manufacturing and automation services in April 2024 with the aim of overseeing the industrial processes and optimizing them.

Regional Insights

It is predictable that the Asia Pacific will dominate the market of the Open Process Automation Systems because of the swift industrialization, the development of vast manufacturing processes, and the growth of the use of the technologies of Industry 4.0 and industrial automation. Even countries like China, Japan, South Korea, and India are massively investing in modernizing industrial infrastructure and adopting open, interoperable automation platforms to improve operational efficiency and flexibility in oil and gas, chemical, and power generation sectors. As an example, Siemens has recently in April 2024 developed its industrial automation and digital manufacturing in Asia Pacific to facilitate advanced and open automation systems in manufacturing plants.

The growth of Europe is expected to be high within the forecast period as more investments in smart manufacturing, digitalization, and industrial cybersecurity solutions are to be made. High degree of sustainable production and excellence in the industrial technologies that the region has is pushing the industries to embrace open and vendor-independent automation systems. As an example, in June 2023, Schneider Electric increased its EcoStruxure Automation Expert platform to accommodate software-defined and interoperable industrial automation settings. In the meantime, North America is a significant market due to the high level of automation technology suppliers and high level of digital process automation, whilst Latin America and the Middle East and Africa are still growing with rising investments in industrialization and energy infrastructure.

Report Scope

Recent Developments

• In August 2024, General Electric Company increased its industrial digital and automation activities to assist the contemporary process industries. The company is also targeting open and interoperable automation systems to enhance the efficiency in operations and flexibility of the system. These are solutions that combine industrial IoT and more advanced analytics to improve monitoring and predictive maintenance. The venture makes GE stronger in the Open Process Automation Systems Market.

List of the prominent players in the Open Process Automation Systems Market:

• ABB Ltd.
• Siemens AG
• Honeywell International Inc.
• Schneider Electric SE
• Emerson Electric Co.
• Rockwell Automation Inc.
• Yokogawa Electric Corporation
• Mitsubishi Electric Corporation
• General Electric Company
• Hitachi Ltd.
• Bosch Rexroth AG
• FANUC Corporation
• Others

The Open Process Automation Systems Market is segmented as follows:

By Component

• Hardware
• Software
• Services

By Deployment Type

• On-Premises
• Cloud-Based

By Architecture

• Open Distributed Control Systems (DCS)
• Modular Control Systems
• Interoperable Automation Platforms

By Industry Vertical

• Oil & Gas
• Chemicals
• Power Generation
• Pharmaceuticals
• Manufacturing

By Application

• Process Control
• Asset Management
• Plant Optimization
• Industrial Monitoring

Regional Coverage:

North America

• U.S.
• Canada
• Mexico
• Rest of North America

Europe

• Germany
• France
• U.K.
• Russia
• Italy
• Spain
• Netherlands
• Rest of Europe

Asia Pacific

• China
• Japan
• India
• New Zealand
• Australia
• South Korea
• Taiwan
• Rest of Asia Pacific

The Middle East & Africa

• Saudi Arabia
• UAE
• Egypt
• Kuwait
• South Africa
• Rest of the Middle East & Africa

Latin America

• Brazil
• Argentina
• Rest of Latin America