Machine Safety - Market Share Analysis, Industry Trends & Statistics, Growth Forecasts (2025 - 2030)

Machine Safety Market Analysis

The machine safety market size at USD 5.58 billion in 2025 and is forecast to climb to USD 8.97 billion by 2030, advancing at a 9.97% CAGR. Heightened regulatory pressure, rapid industrial automation and the growing convergence of functional-safety with cybersecurity are the core forces behind this growth. Europe’s upcoming Machinery Regulation 2023/1230 is compelling manufacturers worldwide to embed Performance Level e functions and to harden safety systems against digital threats ec.europa.eu. Asia-Pacific’s expanding electronics and automotive bases are accelerating demand for adaptive safeguarding, while North American food and beverage processors are pursuing digital retrofits that combine Industry 4.0 data flows with safety compliance automate.org. Vendors that can offer integrated safety PLCs, predictive-maintenance analytics and certified cyber-secure architectures are capturing share as end-users transition from hard-wired relays to software-defined safety logic.

Global Machine Safety Market Trends and Insights

Accelerated Adoption of Collaborative Robots in Electronics Assembly Lines across East Asia

Electronics producers in China, South Korea and Taiwan are replacing isolated industrial robots with collaborative units that share workspaces with operators. Dynamic presence-sensing light curtains and 3D vision guard zones now stop cobots only when a person is at risk, lifting overall line productivity by 18% while cutting recordable incidents by 27%. AI-powered safety logic embedded in the robot controller enables speed-and-separation monitoring rather than hard stops, which further shortens cycle times. Component vendors supplying certified safety scanners, safe torque off drives and software-configurable PLCs are therefore experiencing outsized order growth from contract electronics manufacturers. The wave of cobot deployment is expected to peak over the next three years as electronics assemblers race to offset regional labor shortages and maintain export competitiveness.

EU Machinery Regulation 2023/1230 Mandating Performance Level e Safety Functions in New Equipment from 2027

The regulation, entering force on 20 January 2027, introduces legally binding PL-e requirements for critical functions and embeds explicit cybersecurity clauses that classify hacking-induced malfunction as a safety hazard. Machine builders supplying the EU must therefore validate that safety-related control parts withstand both random hardware faults and intentional attacks. This dual compliance need is fueling demand for integrated safety-security controllers and certified secure remote-update mechanisms. Because the rule applies directly without national transposition, suppliers can scale one architecture across all 27 member states, streamlining product-development pipelines. Preparatory spending on risk assessments, software patch management and digital-twin simulation is already evident among German and Italian OEMs looking to avoid last-minute redesigns.

High Integration Complexity of Safety Networks with Legacy Control Architecture in Brownfield Sites

Many 1980s-era distributed-control systems use proprietary buses lacking deterministic bandwidth for safety traffic. Integrators therefore resort to protocol gateways and shadow controllers, inflating project costs by up to 65% and extending commissioning windows. Continuous-process plants resist such downtime, opting for minimum-compliance fixes that slow the adoption of networked safety. Although vendors are releasing “plug-in” migration bridges and simulation-based validation tools, the structural mismatch between legacy hardware and modern functional-safety standards will persist until large-scale control-system overhauls occur.

Other drivers and restraints analyzed in the detailed report include:

1. Rapid Brownfield Digital Retrofit Programs in North-American Food & Beverage Plants Incorporating Safety I/O-Link Sensors
2. Surge in LNG Megaprojects in the Middle East Elevating Demand for SIL-3 Rated Emergency Shutdown Systems
3. Capital Budget Freezes in Automotive Tier-2 Suppliers Amid EV Demand Volatility

For complete list of drivers and restraints, kindly check the Table Of Contents.

Segment Analysis

Individual components continued to dominate in 2024 with a 65% machine safety market share due to their plug-and-play compatibility with brownfield equipment. However, embedded components are forecast to outpace at an 11.8% CAGR as PLCs, drives and HMIs ship with integrated safety firmware, trimming cabinet space and wiring. Automotive body-in-white lines illustrate the trend: a single controller now hosts both standard motion profiles and PL-e interlock logic, eliminating duplicate processors. In electronics assembly, microcontroller-based safety co-processors handle reaction times below 10 ms, satisfying the machine safety market size requirement for high-speed pick-and-place equipment. Suppliers that certify combo-control chips under both IEC 61508 and ISO 26262 are positioned to capture OEM design wins as cost parity with discrete relays approaches.

The retrofit arena still favors discrete light curtains and interlocks because installers can swap hardware during weekend shutdowns without revalidating the base PLC code. Yet even here, “slice” I/O modules with dual-channel safety inputs are edging in, allowing cabinets to host standard and safety wiring on one backplane. Regulatory harmonization across Europe and the Americas is also tilting investment toward embedded solutions; once a safety CPU is certified, software changes can be field-downloaded rather than rewiring physical relays, delivering faster ROI especially in seasonal packaging operations.

Presence-sensing safety sensors accounted for 30% of revenue in 2024, underpinning virtually every safeguarding scheme from press brakes to palletizers. Optical and radar variants now incorporate muting logic that differentiates payload from personnel, minimizing nuisance stops in conveyor systems. Safety PLCs represent the fastest-growing sub-segment at 12.5% CAGR because flexible manufacturing demands programmable zones and high-speed logic reconfiguration. The transition from hard-wired contacts to parameterized function blocks reduces electrical drawings by up to 60% and enables digital twins that validate changes before deployment.

Modern safety PLCs also embed secure-boot firmware and encrypted communications, satisfying the dual requirement of cybersecurity and functional safety posed by the EU Machinery Regulation. The machine safety market size for safety PLCs is further lifted by the migration of OEMs to unified control panels where one CPU executes both standard IEC 61131 tasks and SIL-3 diagnostics. Component suppliers are bundling pre-certified libraries for safe torque off, safe limited speed and safe position, shortening application development time for machine builders.

The Machine Safety Market Report is Segmented by Implementation (Individual Components, Embedded Components, and More), Component (Presence-Sensing Safety Sensors, Safety Light Curtains, Safety Laser Scanners, and More), Application (Material Handling, Robotics & Collaborative Robots, and More), End User (Automotive, Food & Beverage, and More), and Geography. The Market Forecasts are Provided in Terms of Value (USD).

Geography Analysis

Europe’s 31% share in 2024 underscores its role as regulatory pacesetter and automation pioneer. German automotive, chemical and machine-tool builders integrate networked safety backbones on virtually every new line, and 68% of installations already stream diagnostic data to central dashboards. Italian packaging OEMs export PL-e compliant fillers to North and South America, amplifying Europe’s technology spillover. The United Kingdom mirrors EU norms to protect export access, while French aerospace plants deploy collaborative-robot guarding to co-locate humans and robots in wing-assembly cells.

Asia-Pacific, projected to post an 11.6% CAGR, is the pivotal growth arena. China’s electronics assemblers rush to meet both domestic GB safety codes and CE marking for export, driving volume orders of light curtains and safe-motion drives. Japan’s robotics makers embed dual-channel torque sensors in arms, enabling built-in ISO 13849 compliance and boosting acceptance of humans and robots in shared workstations. India sees multinational pharma and automotive OEMs installing Category 3 and 4 systems at new greenfield sites, lifting local awareness and triggering supplier localization. South Korean chip fabs procure SIL-rated valve-manifolds for ultrapure chemical lines, combining functional-safety with low-particulate construction to safeguard both personnel and wafers.

North America remains a technology leader, yet growth is steadier. US processors upgrade safety to mitigate liability and insurance costs, with 42% of food plants planning major modernizations in 2025. Canada’s mining sector adopts wireless SIL-3 emergency-stop networks for haul-truck corridors. Latin American adoption is uneven: Brazil’s automotive clusters align with EU and US customer mandates, whereas smaller factories delay investments. The Middle East & Africa region expands fastest in high-risk energy sectors, installing integrated fire-and-gas plus ESD systems at refineries and LNG terminals.

List of Companies Covered in this Report:

1. Rockwell Automation, Inc.
2. Siemens AG
3. Schneider Electric SE
4. Omron Corporation
5. Sick AG
6. Pilz GmbH and Co. KG
7. Mitsubishi Electric Corporation
8. ABB Ltd.
9. Honeywell International Inc.
10. Keyence Corporation
11. IDEC Corporation
12. Banner Engineering Corp.
13. Phoenix Contact GmbH and Co. KG
14. Datalogic S.p.A.
15. Bihl + Wiedemann GmbH
16. Euchner GmbH + Co. KG
17. Leuze electronic GmbH + Co. KG
18. Wenglor sensoric GmbH
19. Rockford Systems LLC
20. Fortress Safety

Additional Benefits:

• The market estimate (ME) sheet in Excel format
• 3 months of analyst support