Advanced Process Control Market Size, Share & Trends | 2031

Report Description

Advanced Process Control Market Outlook 2031

The global advanced process control market size was USD 1.83 Bn in 2022 and is likely to reach USD 4.07 Bn by 2031, expanding at a CAGR of 9.3% during 2023–2031. The market growth is attributed to the rising adoption of the advanced process control system in various end-user industries for improving quality, efficiency in operations, safety, and process automation & optimization.

Advanced process control (APC) is referred to the various techniques and technological solutions implemented within industrial processes to refine control over existing processes or address existing peculiar problems related to a process. In advanced process control systems, different hardware and software are clubbed together to better control the overall control loop requirements.

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Insightful knowledge of the industrial processes, knowing the drawbacks of the existing control systems, and the dynamics of the processes are essential aspects for implementing APC process control. A better understanding of the process is essential in adopting the most suitable technology and method for process control. 

The main objective behind the implementation of the advanced process control system is to enhance control over the processes that contribute to production. Constant control application over processes helps in simplifying the production process and makes the prediction of output results more accurate. In addition, increased control over processes helps in getting rid of process reruns and reduces the wastage of resources. The reduced reruns and resource use optimization is beneficial for further cutting the total cost involved in the manufacturing process.

Some of the key benefits provided by advanced process control devices or systems are remarkable improvements in product profitability, reduction in energy consumption, minimization of equipment downtime, and highly improved product quality and consistency, among others. Additionally, APC process control is beneficial in reducing environmental emissions and enhancing process safety.

COVID-19 Impact on Advanced Process Control Market

The market report finds that the COVID-19 pandemic affected the growth of the advanced process control market. Several verticals that come under the end-user of APC process control technology experienced operation slowdown or complete halt, due to lockdown restrictions imposed by several governments across the world. The demand for advanced control solutions was affected during the peak time of the pandemic, owing to supply chain and logistics-related issues.

The long-term effect of the COVID-19 pandemic on the advanced process control market is projected to be positive as companies across the sectors have started adopting process automation solutions such as APC into their operations. For improving productivity, reducing resource losses, and cutting labor costs during the pandemic. The data generated from various processes is aiding in reducing lapses in the processes and bringing more efficiency to overall industrial operations using advanced process control technologies.

Advanced Process Control Market Dynamics

The research report presents a complete market overview by providing detailed information about the current market trends, existing drivers, growth opportunities and potentials, and emerging challenges. The global advanced process control market report has up-to-date insights about market scenarios that can shape the overall market performance and output during the forecast period, 2022 to 2030.

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Major Trends

Automation is one of the major ongoing trends across industrial sectors, which is significantly aiding the market growth. The rapid rise of technological solutions and advanced machines has increased the possibilities of automation in several sectors. Advanced process control systems are playing a key role in facilitating seamless automation in industrial processes ranging from manufacturing to logistics.

The APC systems maintain the operations at optimal levels, by adjusting key variables in real-time to improve quality and productivity. Advanced control solutions facilitate intelligent process automation and reduce operational risks by eliminating errors involved in minute-to-major processes. The APC implementation allows maximum customization, which enables fulfilling all the parameters closer to the limits.

Drivers

The high demand for quality control and process optimization in several end-user industries across the world is expected to drive the advanced process control industry in the coming years. Advanced process control systems enable extreme control over each stage of industrial processes, owing to which quality and optimization variables can be preprogrammed.

Manual process handling always has possibilities of errors at every stage. As the industrial processes are growing larger and more complex due to quality and productivity requirements in every industry, the need for advanced systems such as APC is growing larger. A small error can cause a big loss to enterprises, which is why firms are looking for advanced control solutions to improve quality and optimize resource use.

Major Restraints

The high initial investment required for implementing advanced control systems is anticipated to hamper the global market growth. Factors such as complex implementation, high-skill requirements, and maintenance need high-cost investment.

In addition, the system needs regular customization, maintenance, and additions based on current business requirements, which requires dedicated high-skills professionals’ support. The cost required for implementing and maintaining the APC system is resulting in companies being cautious about investing in deploying APC systems in their operations.

Growth Opportunities

The development of cost-effective and advanced optimization technology tools for improving the reliability and sustainability of industrial operations is projected to create lucrative growth opportunities for the global market. The consumer demands for products are consistently increasing in every industry globally, due to rising population, urbanization, changing lifestyles, growing disposable income, and other such factors.

Companies require to generate higher output in a limited time window and optimized resource utilization. Quality improvements and consistency are also highly necessary. The availability of advanced technology tools such as cloud computing optimization tools, artificial intelligence tools, Internet of Things (IoT) devices, and others, is anticipated to increase the implementation of advanced control systems in the coming years.

Scope of Advanced Process Control Market Report

The global advanced process control market research report includes an assessment of the market trends, market segments, and regional markets. Overview and dynamics have also been included in the report.

Advanced Process Control Market Segment Insights

What are Major Reasons for High Revenue Generation in Services Segment in Advanced Process Control Market?

Based on revenue source, the global advanced process control industry is divided into hardware, software, and services. The services segment is anticipated to hold the major share of the market revenue owing to the large installed base of advanced process control (APC) systems in developed regions such as North America and Europe.

Advanced process control services are highly demanded by enterprises to improve sustainability, save energy, optimize processes to reduce reruns, and eliminate errors, among others. The increasing industrial automation and rising production requirements are projected to drive the demand for APC services in the coming years.

Software segment is anticipated to grow rapidly in the global market owing to rising demand for advanced process control software in various end-user industries. Software solutions are customized as per the production requirements, which helps in improving profitability by enhancing quality, optimizing resource usage, and increasing throughput. Advanced process control software systems include model-based software solutions which are used to direct process workings. The APC applications are commonly identified as model predictive control or multivariable predictive control (MPC).

Which Major Factors Influence the Significant Growth of the Multivariable Model Predictive Control Segment?

On the basis of type, the global market is segregated into advanced regulatory control, inferential control, multivariable model predictive control, compressor control, and sequential control. The multivariable model predictive control (MPC) segment is projected to register a considerable CAGR during the forecast period. The segment growth is attributed to expanding use of MPC as an automated multivariable process control technology in various industries.

MPC is considered an important tool for optimizing plant performance on an ongoing basis. It is widely implemented by several end-user industries optimizing material and utility utilization, minimizing pollution, reducing waste generation, and maximizing production.

Advanced regulatory control (ARC) segment is expected to hold a considerable share of the market during the forecast period. ARC acts based on errors that occurred during the process, while MPC acts based on predictive maintenance models. Advanced regulatory control is beneficial for improving stability and performance.

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What are Major Reasons for High Revenue Generation in Oil & Gas?

Based on end-user, the global advanced process control industry is divided into oil & gas, semiconductors, pharmaceuticals, food & beverages, water & wastewater, energy & power, petrochemicals, and chemicals. The oil and gas segment held the major share of the market revenue in 2021 and is anticipated to consistently generate high revenues during the projection period.

The segment growth is attributed to the growing adoption of APC systems for real-time optimization at oil & gas plants. The processes in the oil & gas plants are complex and require extra control for consistent quality improvements. The advanced process control software support improving quality and reducing resource waste in the oil & gas industry. Energy & power segment is projected to witness rapid growth during the forecast period in the global market.

According to estimates by several studies, advanced process controls (APC) systems implementation helps in energy saving, ranging from 5% to 15% depending on operations and processes. Utility management is a complex process and requires regular maintenance. The APC systems can be designed in a way to reduce process failures and costs on utility. Furthermore, the APC systems can also support optimizing energy generation processes.

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Why is Asia Pacific Dominating the Advanced Process Control Market?

In terms of region, the global advanced process control market is classified as Asia Pacific, North America, Latin America, Europe, and Middle East & Africa. The market size of Asia Pacific is expected to dominate the market during the forecast period, due to the high demand for efficient production systems that optimize energy and resource use in different industries. The market growth in the region is also supported by increasing manufacturing across industries and the rising construction of power plants in developing economies such as India, China, and Japan.

North America is projected to grow rapidly during the projection period, owing to the growing adoption of technology solutions for streamlining operations across industries. The growing focus on industrial automation is also expected to fuel the market. Furthermore, the rapid growth of APC solutions in the semiconductor industry, nuclear power plants, and oil & gas industry is anticipated to help the market growth in the region.

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