Global Modular Automation Market Size, Study & Forecast, by Type (Modular Type Packages and Modular DCS), by Mobility (Semi-automatic and Fully Automatic), by Component (Robot Controllers, I/O Modules, Drives & Motors, Sensors & Actuators, and Safety) and

The Global Modular Automation Market is valued at approximately USD 4.8 billion in 2024 and is expected to grow at a CAGR of more than 7.9% over the forecast period 2025–2035. Modular automation refers to an adaptable system design strategy that integrates modular and scalable components into automation architecture, enabling manufacturers to reconfigure and optimize production processes with minimal downtime. This model is rapidly gaining prominence across industrial sectors, offering flexibility, reduced operational costs, and the ability to swiftly adapt to changing market demands. The market’s upward trajectory is largely influenced by increasing adoption of Industry 4.0 technologies, the expanding need for smart manufacturing systems, and the transition toward fully digitalized industrial environments. Furthermore, the emphasis on efficiency enhancement and mass customization in modern production ecosystems has intensified the demand for modular and flexible automation platforms globally.

As the industrial landscape undergoes a paradigm shift, modular automation is redefining how manufacturing facilities operate. The surge in demand for automated systems across industries such as automotive, electronics, and pharmaceuticals has created significant momentum for modular automation technologies. These systems not only enhance productivity and process control but also enable companies to achieve agile manufacturing goals. According to the International Federation of Robotics (IFR), global industrial robot installations surpassed 530,000 units in 2023, marking a record high, with modular automation systems forming a crucial part of this revolution. Moreover, the growing integration of AI, IoT, and digital twin technologies into modular architectures is transforming traditional assembly lines into intelligent, self-optimizing systems. However, challenges such as high initial investment and complexity in system integration could slightly hinder market expansion during the forecast period.

The detailed segments and sub-segments included in the report are:

By Type:
• Modular Type Packages
• Modular DCS

By Mobility:
• Semi-automatic
• Fully Automatic

By Component:
• Robot Controllers
• I/O Modules
• Drives & Motors
• Sensors & Actuators
• Safety

By End-user Industry:
• Manufacturing
• Automotive
• Food & Beverages
• Pharmaceuticals
• Electronics
• Others

By Region:

North America
• U.S.
• Canada

Europe
• UK
• Germany
• France
• Spain
• Italy
• Rest of Europe

Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• Rest of Asia Pacific

Latin America
• Brazil
• Mexico

Middle East & Africa
• UAE
• Saudi Arabia
• South Africa
• Rest of Middle East & Africa

Semi-automatic Systems Expected to Dominate the Market

Semi-automatic modular automation systems are expected to hold the largest market share during the forecast period. These systems act as a vital bridge between manual and fully automated operations, providing manufacturers with flexibility and cost-efficiency. Semi-automatic systems are widely implemented in small and medium-sized enterprises (SMEs) that seek scalable solutions without committing to the capital intensity of full automation. Their adoption is further fueled by their ability to maintain process consistency while allowing human intervention for complex or non-repetitive tasks. The adaptability and ease of reconfiguration in semi-automatic modular setups make them particularly suitable for industries characterized by high product variation and moderate production volumes. However, with technological advancement and declining costs, fully automated systems are anticipated to grow at a faster pace throughout the forecast timeline.

Robot Controllers Lead in Revenue Contribution

When analyzing the modular automation market by component, the robot controllers segment currently contributes the highest revenue share. These controllers serve as the brain of modular automation systems, enabling precise coordination among robots, sensors, and actuators to perform synchronized operations efficiently. The dominance of this segment stems from the increasing deployment of collaborative robots (cobots) in manufacturing environments and the rising demand for flexible robotic control systems that can be rapidly integrated into modular production cells. Meanwhile, sensors and actuators are emerging as a pivotal growth segment, driven by advancements in predictive maintenance and data-driven automation technologies. As real-time feedback and autonomous decision-making become integral to industrial systems, these intelligent components are poised to accelerate future growth across multiple industries.

The key regions analyzed for the Global Modular Automation Market include North America, Europe, Asia Pacific, Latin America, and the Middle East & Africa. North America currently leads the market due to the strong presence of advanced manufacturing facilities, significant investments in smart factory infrastructure, and widespread adoption of digital control systems. The U.S., in particular, has witnessed extensive deployment of modular automation solutions across the automotive and pharmaceutical sectors, fueled by technological maturity and a robust innovation ecosystem. Meanwhile, Asia Pacific is forecasted to exhibit the fastest growth rate over the coming decade, primarily driven by the expanding industrial automation base in China, India, and South Korea. Favorable government policies promoting industrial modernization, coupled with increasing foreign investments in smart manufacturing projects, are creating fertile ground for modular automation adoption in the region.

Major market players included in this report are:
• ABB Ltd.
• Siemens AG
• Rockwell Automation, Inc.
• Mitsubishi Electric Corporation
• Schneider Electric SE
• Honeywell International Inc.
• Emerson Electric Co.
• Omron Corporation
• FANUC Corporation
• Yokogawa Electric Corporation
• Bosch Rexroth AG
• Beckhoff Automation GmbH & Co. KG
• B&R Industrial Automation GmbH
• Parker Hannifin Corporation
• Festo SE & Co. KG

Global Modular Automation Market Report Scope:
• Historical Data – 2023, 2024
• Base Year for Estimation – 2024
• Forecast period – 2025–2035
• Report Coverage – Revenue forecast, Company Ranking, Competitive Landscape, Growth factors, and Trends
• Regional Scope – North America; Europe; Asia Pacific; Latin America; Middle East & Africa

The objective of the study is to define market sizes of different segments & countries in recent years and to forecast the values for the coming years. The report is designed to incorporate both qualitative and quantitative aspects of the industry within the countries involved in the study. The report also provides detailed information about crucial aspects such as driving factors and challenges, which will define the future growth of the market. Additionally, it incorporates potential opportunities in micro-markets for stakeholders to invest, along with a detailed analysis of the competitive landscape and product offerings of key players. The detailed segments and sub-segments of the market are explained below:

Key Takeaways:
• Market Estimates & Forecast for 10 years from 2025 to 2035.
• Annualized revenues and regional-level analysis for each market segment.
• Detailed analysis of the geographical landscape with country-level analysis of major regions.
• Competitive landscape with information on major players in the market.
• Analysis of key business strategies and recommendations on future market approach.
• Analysis of the competitive structure of the market.
• Demand side and supply side analysis of the market. Show more