Global Advanced Process Control Market Size, Share & Trends Analysis Report By Enterprise Size (Large Enterprises, and Small & Medium Enterprises (SMEs)), By Component, By Technology, By Solution, By End Use, By Regional Outlook and Forecast, 2025 - 2032

The Global Advanced Process Control Market size is expected to reach $5.01 billion by 2032, rising at a market growth of 10.3% CAGR during the forecast period.

The North America segment recorded 36% revenue share in the market in 2023. The strong presence of major industries such as oil & gas, chemicals, pharmaceuticals, and power generation has fuelled the demand for APC solutions in the region. Companies across these sectors increasingly adopt automation and AI-driven process control technologies to enhance operational efficiency, reduce costs, and ensure regulatory compliance.

Industries such as oil and gas, pharmaceuticals, chemicals, and manufacturing are constantly under pressure to enhance productivity, reduce waste, and optimize energy consumption. Traditional process control methods often fail to achieve the precision and efficiency required in modern industrial settings. Advanced Process Control (APC) solutions provide real-time process adjustments, helping industries improve yield, reduce variability, and enhance operational efficiency. In conclusion, the rising demand for process optimization and operational efficiency in industries drives the market's growth.

Additionally, The shift towards cloud-based APC solutions transforms industrial automation by offering scalability, flexibility, and remote accessibility. Unlike traditional on-premise systems, cloud-based APC allows industries to store and process vast amounts of real-time data without investing heavily in IT infrastructure. This reduces the burden of maintaining costly hardware while enabling seamless integration with Industrial Internet of Things (IIoT) systems. Thus, the growing adoption of cloud-based advanced process control solutions propels the market's growth.

However, As industrial operations become more interconnected, cybersecurity risks and data privacy concerns pose significant challenges to APC adoption. With increased reliance on cloud computing, IIoT, and remote monitoring, APC systems have become potential cyberattack targets. Hackers can exploit vulnerabilities in networked industrial control systems, leading to data breaches, operational disruptions, or even catastrophic failures in critical industries such as oil & gas or power generation. Thus, industrial automation's cybersecurity risks and data privacy concerns hamper the market's growth.

Enterprise Size Outlook

Based on enterprise size, the market is segmented into small & medium enterprises (SMEs) and large enterprises. The small & medium enterprises (SMEs) segment acquired 32% revenue share in the market in 2023. The growing need for cost-effective and scalable APC solutions has driven SMEs to invest in automation technologies to improve productivity and operational efficiency. Cloud-based APC solutions and subscription-based models have made it easier for SMEs to adopt advanced process control without significant upfront costs.

Component Outlook

Based on component, the market is characterized into hardware, software, and service. The demand for hardware components, including controllers, sensors, and embedded systems, is driven by their essential role in ensuring real-time monitoring and control of industrial processes. Industries such as oil & gas, chemicals, and manufacturing rely on robust and high-performance hardware to optimize operational efficiency, reduce downtime, and enhance process stability.

Technology Outlook

On the basis of technology, the market is classified into advanced regulatory control (ARC), multivariable model predictive control (MPC), sequential control, inferential control, and compressor control. MPC technology's ability to handle complex, multi-input, and multi-output processes has made it highly valuable for industries requiring precise and efficient control mechanisms. MPC helps reduce process fluctuations, improve product quality, and optimize resource utilization by predicting future system behavior and making real-time adjustments.

Solution Outlook

By solution, the market is divided into energy management & optimization, asset performance optimization, process performance, operation management, workforce management, and others. The growing need for maximizing equipment efficiency, reducing unplanned downtime, and extending asset lifespan has driven the adoption of asset performance optimization solutions. Industries such as oil & gas, manufacturing, and power generation rely on these solutions to monitor asset health in real-time, predict failures, and optimize maintenance schedules.

End Use Outlook

By end use, the market is segmented into oil and gas, chemicals, pharmaceuticals, energy & power, paper & pulp, mining, minerals, & metals, food & beverages, and others. The rising demand for high-quality chemical products and the need for stringent process control have led chemical manufacturers to invest in APC technologies. These solutions enhance production consistency, reduce waste, and improve overall process efficiency by optimizing reaction conditions and monitoring critical parameters.

Regional Outlook

Region-wise, the market is analyzed across North America, Europe, Asia Pacific, and LAMEA. The Europe segment witnessed 31% revenue share in the market in 2023. The region’s growing focus on sustainable manufacturing, energy efficiency, and smart industrial operations has contributed to the rising adoption of APC technologies. European industries, particularly in chemicals, energy, and automotive manufacturing, leverage APC solutions to optimize production processes and meet stringent environmental regulations.

The leading players in the market are competing with diverse innovative offerings to remain competitive in the market. The above illustration shows the percentage of revenue shared by some of the leading companies in the market. The leading players of the market are adopting various strategies in order to cater demand coming from the different industries. The key developmental strategies in the market are Acquisitions, and Partnerships & Collaborations.

Recent Strategies Deployed in the Market

• Feb-2025: Emerson Electric Co. expands its Impact Partner Network to provide on-site servicing for select measurement instrumentation devices across North America. The network enhances local support, diagnostics, and calibration for Rosemount™ and Micro Motion™ products, improving safety, reliability, and efficiency in industrial automation.
• Aug-2024: ABB Ltd. launched next-generation electromagnetic flowmeters, ProcessMaster and AquaMaster, featuring high accuracy, modularity, and IoT connectivity. These innovations enhance process monitoring, support Advanced Process Control (APC) systems, and enable real-time optimization, predictive maintenance, and flexible automation in industrial and utility applications.
• May-2024: ABB Ltd. is expanding its Advanced Process Control (APC) solutions with a new implementation at Södra Cell’s Värö pulp mill. This enhancement of ABB Ability™ System 800xA® strengthens ABB’s APC offerings, optimizing bleaching processes, improving efficiency, and driving digital transformation in pulp manufacturing.
• Feb-2024: GE Vernova division of General Electric Company launched Proficy for Sustainability Insights, an AI-based software that integrates operational and sustainability data to optimize resource usage, reduce costs, and enhance efficiency. It helps industrial firms meet sustainability goals while improving productivity, profitability, and regulatory compliance.
• Nov-2023: Emerson Electric Co. acquires Afag and National Instruments (NI) to expand its automation, motion control, and test & measurement capabilities. These acquisitions enhance Emerson’s industrial software, efficiency, and market reach, strengthening its position in factory automation, sustainability, and digital transformation.

List of Key Companies Profiled

• ABB Ltd.
• Siemens AG
• Emerson Electric Co.
• General Electric Company
• Honeywell International Inc.
• Mitsubishi Electric Corporation
• Panasonic Holdings Corporation
• Rockwell Automation, Inc.
• SAP SE
• Onto Innovation Inc.

Global Advanced Process Control Market Report Segmentation

By Enterprise Size

• Large Enterprises
• Small & Medium Enterprises (SMEs)

By Component

• Software
• Hardware

Control Systems

Computing Systems

Interface, Display & Others

• Services

By Technology

• Advanced Regulatory Control (ARC)
• Multivariable Model Predictive control (MPC)
• Inferential control
• Sequential control
• Compressor control

By Solution

• Energy Management & Optimization
• Asset Performance Optimization
• Process Performance
• Operation Management
• Workforce Management & Others

By End Use

• Oil & Gas
• Chemicals
• Mining, Minerals, & Metals
• Pharmaceuticals
• Energy & Power
• Food & Beverages
• Paper, Pulp & Others

By Geography

• North America

US

Canada

Mexico

Rest of North America

• Europe

Germany

UK

France

Russia

Spain

Italy

Rest of Europe

• Asia Pacific

China

Japan

India

South Korea

Singapore

Malaysia

Rest of Asia Pacific

• LAMEA

Brazil

Argentina

UAE

Saudi Arabia

South Africa

Nigeria

Rest of LAMEA