Advanced Process Control Market Size (2024 - 2029)

Advanced Process Control Market Analysis

The Advanced Process Control Market size is estimated at USD 2.83 billion in 2024, and is expected to reach USD 4.31 billion by 2029, at a CAGR of 8.83% during the forecast period (2024-2029).

Advanced process control (APC) refers to a set of sophisticated techniques and technologies used in industrial process control systems to enhance the performance and efficiency of manufacturing processes. APCs are supplementary to basic process controls and are introduced to target specific performance or economic enhancements. Despite being established over 30 years ago, APC has surged in prominence recently, with global factories prioritizing process optimization. These solutions seamlessly merge information, control, power, and safety measures, addressing the rising demand for cost-effective energy, adhering to strict government regulations, and reducing expenses.

• APC encompasses a sophisticated interplay of hardware and software, working in unison to optimize control loops. The primary objective of APC is to enhance the performance of processes integral to production. By maintaining consistent control, APC not only streamlines the production process but also renders the output results more predictable.
• Industries are increasingly turning to automation solutions to boost productivity and enhance operational efficiency. APC systems leverage sophisticated algorithms and predictive modeling to streamline processes, minimize downtime, and elevate overall performance. As businesses aim to amplify output while curtailing costs, the integration of APC technologies becomes indispensable. This trend is driven by the relentless pursuit of operational excellence and the need to stay competitive in a rapidly evolving market landscape.
• As industries face heightened scrutiny regarding safety standards, APC systems are being adopted to improve operational safety. These systems can automate safety protocols, monitor processes in real-time, and quickly identify anomalies that could lead to hazardous situations. By minimizing human error and enhancing response time, APC systems help prevent accidents and ensure compliance with safety regulations.
• Integrating APC systems with existing infrastructure and legacy systems presents significant challenges. Many industries continue to operate with outdated technology, which complicates the seamless incorporation of advanced control solutions. This complexity can lead to increased costs and extended deployment timelines, thereby deterring potential adopters from investing in these technologies.
• As legacy control systems age, industrial players are increasingly focusing on upgrading and modernizing them to stay competitive. Modernization typically involves integrating more advanced control algorithms, enhancing digital capabilities, and improving overall system robustness.
• For instance, in August 2024, ABB implemented its advanced process control solution, the ABB Ability Expert Optimizer system, at the Tokuyama Nanyo cement plant in Japan. With the commissioning of the ABB Ability Expert Optimizer, Tokuyama can now achieve a reduction of approximately 3% in thermal energy consumption in the kiln, all while upholding the operational quality at the Nanyo plant, recognized as one of Japan's largest single factories. This industrial software harnesses advanced process control techniques, including linear and non-linear model predictive control, fuzzy logic, and neural networks, to consistently and accurately automate optimal operational decisions.

Advanced Process Control Industry Segmentation

APC operates at the supervisory level, optimizing process units in real time. Utilizing mathematical models, algorithms, or statistical analyses—typically executed on a computer network and monitored from the control room—this program predicts and manages process behavior. APC applications enhance plant operations by overseeing lower-level regulatory controllers, ensuring safety, and making minimal adjustments to the existing regulatory control system. By harnessing insights from decision-making models like artificial intelligence, machine learning, and digital twins, the APC application steers the plant in a safe, dynamic, and responsive manner.

The advanced process control market is segmented by type (advanced regulatory control, model predictive control, and other types), end-user industry (oil and gas, chemicals and petrochemicals, pharmaceutical, food and beverage, energy and power, cement industry, metal processing, pulp and paper, and other end-user industries), and geography (North America, Europe, Asia-Pacific, Latin America, and Middle East and Africa). The market sizes and forecasts are provided in terms of value (USD) for all the above segments.