Global Personal Computer (PC)-Based Automation Market Size, Share and Trends Analysis Report – Industry Overview and Forecast to 2032

Personal Computer (PC)-Based Automation Market Size

• The global personal computer (PC)-based automation market size was valued at USD 40.30 billion in 2024 and is expected to reach USD 60.23 billion by 2032, at a CAGR of 5.15% during the forecast period
• The market growth is largely fueled by the increasing adoption of industrial automation and the technological advancement of PC-based control systems, enabling real-time monitoring, process optimization, and integration with IoT and Industry 4.0 initiatives across diverse industrial sectors
• Furthermore, rising demand for flexible, scalable, and high-performance automation solutions is driving the adoption of PC-based systems in both discrete and process industries. These converging factors are accelerating the implementation of PC-based automation solutions, thereby significantly boosting market growth

Personal Computer (PC)-Based Automation Market Analysis

• PC-based automation systems are advanced industrial solutions that integrate hardware components such as PLCs, industrial PCs, HMIs, and SCADA software with control and monitoring applications. They enable precise process control, data analytics, and seamless integration across production and manufacturing environments
• The escalating demand for PC-based automation is primarily fueled by industries seeking operational efficiency, enhanced productivity, predictive maintenance, and reduced downtime. Growing investments in smart factories, digital transformation initiatives, and modernization of legacy automation infrastructure further support market expansion
• North America dominated the personal computer (PC)-based automation market in 2024, due to widespread adoption of industrial automation and advanced manufacturing technologies
• Asia-Pacific is expected to be the fastest growing region in the personal computer (PC)-based automation market during the forecast period due to rapid industrialization, urbanization, and rising adoption of automation technologies in countries such as China, Japan, and India
• Hardware segment dominated the market with a market share of 48.3% in 2024, due to the essential role of physical components such as controllers, industrial PCs, and operator panels in establishing and maintaining automation systems. Hardware investments remain critical for ensuring operational efficiency, reliability, and long-term system performance across industries. Increasing focus on industrial modernization and upgrading legacy systems has further strengthened the demand for hardware offerings

Report Scope and Personal Computer (PC)-Based Automation Market Segmentation

Personal Computer (PC)-Based Automation Market Trends

Growing Adoption of IoT-Enabled PC-Based Automation

• The PC-based automation market is experiencing strong growth driven by the increasing integration of Internet of Things (IoT) technologies, enabling smarter and more connected industrial operations. This integration facilitates real-time data collection, remote monitoring, and predictive maintenance, thereby enhancing manufacturing efficiency and reducing downtime
  • For instance, Nielsoft launched comprehensive Industry 4.0 solutions in India in 2024, combining PC-based automation with IoT-enabled sensors and cloud analytics to optimize factory, shop floor, and enterprise-level operations. Leading global players such as Siemens and Beckhoff are embedding IoT capabilities into their PC automation systems to support intelligent manufacturing environments
• IoT-enabled PC-based automation allows seamless communication between machines, devices, and control systems, supporting adaptive control and data-driven decision-making. These capabilities are transforming traditional manufacturing by enabling smarter workflows, reducing waste, and enhancing flexibility across production lines
• Advancements in software, including AI-driven analytics and cloud computing integration, are further accelerating PC-based automation adoption. The ability to consolidate control functions within ruggedized PCs reduces hardware costs while enhancing processing speed and system reliability, key factors supporting Industry 4.0 transition
• Manufacturers in automotive, electronics, pharmaceuticals, and food & beverage sectors are rapidly adopting PC-based automation solutions, configuring systems for discrete, process, and building automation. The growing focus on digital transformation strategies amplifies demand for scalable, flexible, and connected PC-based control platforms
• The continued fusion of IoT and PC-based automation is expected to be a dominant trend, supporting smart manufacturing innovation and efficiency improvements. This convergence is projected to drive sustained market expansion

Personal Computer (PC)-Based Automation Market Dynamics

Driver

Increased Focus on Industry 4.0

• The global push toward Industry 4.0 and smart manufacturing is a major driver for PC-based automation market growth. The demand for intelligent, interconnected systems that support real-time analytics, predictive maintenance, and remote management underpins broad adoption of PC-based solutions that enable these capabilities
  • For instance, ABB introduced the Ability BeerMaker solution in early 2024, demonstrating the use of PC-based automation to optimize processes in brewing with real-time monitoring and connectivity. Cyklop International’s acquisition of Polaris Systems reflects industry consolidation around integrated automation solutions supporting Industry 4.0 practices
• Manufacturers seek automation systems that provide operational flexibility, facilitate integration with industrial IoT devices, and offer enhanced control over complex production processes. PC-based automation, leveraging commercial off-the-shelf hardware and adaptable software, fulfills these requirements economically and efficiently
• Industry 4.0 emphasis is especially pronounced in automotive, electronics, and pharmaceuticals, where quality control, traceability, and customization demand advanced automation frameworks. Growing government initiatives and private investments in smart factories further boost PC-based automation adoption worldwide
• This focus on digital transformation and automation modernization supports continued market growth by enabling industries to enhance productivity, reduce costs, and improve competitiveness through technology-driven manufacturing evolution

Restraint/Challenge

Complexity of Integration

• Integrating PC-based automation systems within existing industrial infrastructure presents a significant challenge due to technical complexity and interoperability issues. Harmonizing legacy equipment, diverse communication protocols, and multiple software platforms requires substantial planning and skilled expertise
  • For instance, many manufacturers face difficulties aligning PC-based controllers with traditional PLCs, SCADA systems, and ERP platforms, which can lead to increased implementation times and unexpected technical challenges. Customized integration solutions often require expensive consultation and development resources
• The need for rigorous testing, security validation, and ongoing system maintenance adds layers of complexity, increasing total cost of ownership and operational risk. Lack of standardized frameworks across industrial IoT ecosystems complicates seamless data exchange and system scalability
• In addition, varying levels of familiarity with advanced automation solutions among workforce members create adoption barriers requiring extensive training and change management. Complexity in integrating AI, cloud computing, and big data analytics further adds to project challenges
• In conclusion, while PC-based automation delivers significant benefits, integration complexity remains a considerable restraint. Overcoming this challenge requires robust planning, open standards, modular system design, and skilled personnel to ensure smooth deployment and operation in increasingly connected industrial environments

Personal Computer (PC)-Based Automation Market Scope

The market is segmented on the basis of components, offerings, sales channel, and industry.

• By Components

On the basis of components, the PC-based automation market is segmented into PLCs, IPCs, HMIs, SCADA, and others. The PLCs segment dominated the largest market revenue share in 2024, driven by their established reliability in controlling industrial processes and ease of integration with existing automation setups. PLCs are widely preferred across manufacturing units for their robust performance, flexibility in programming, and ability to handle complex control tasks. Their compatibility with a wide range of industrial sensors and actuators further strengthens their adoption. Continuous advancements in PLC technology, including modular designs and enhanced connectivity options, support their dominance in the market.

The IPCs segment is expected to witness the fastest growth rate from 2025 to 2032, fueled by the rising demand for compact, high-performance computing systems in automation applications. Industrial PCs provide advanced processing capabilities, support for diverse software applications, and seamless integration with IoT and cloud platforms. Their flexibility in handling real-time data processing and analytics makes them particularly attractive for modern, data-driven automation systems.

• By Offerings

On the basis of offerings, the PC-based automation market is segmented into hardware, software, and others. The hardware segment dominated the largest market revenue share of 48.3% in 2024, driven by the essential role of physical components such as controllers, industrial PCs, and operator panels in establishing and maintaining automation systems. Hardware investments remain critical for ensuring operational efficiency, reliability, and long-term system performance across industries. Increasing focus on industrial modernization and upgrading legacy systems has further strengthened the demand for hardware offerings.

The software segment is anticipated to witness the fastest growth from 2025 to 2032, driven by the growing need for advanced automation, analytics, and control software. Software solutions provide capabilities such as real-time monitoring, predictive maintenance, and integration with cloud-based platforms, enabling intelligent and connected automation ecosystems. Rising adoption of Industry 4.0 and smart manufacturing initiatives is accelerating software demand, especially for advanced SCADA and HMI applications.

• By Sales Channel

On the basis of sales channel, the PC-based automation market is segmented into direct sales and indirect sales. The direct sales segment dominated the largest market revenue share in 2024, driven by the tendency of large industrial clients to procure automation solutions directly from manufacturers. Direct engagement ensures tailored solutions, better technical support, and streamlined integration with existing systems. Companies often prefer this channel to establish long-term service contracts and reduce dependency on intermediaries.

The indirect sales segment is expected to witness the fastest growth rate from 2025 to 2032, fueled by the expansion of distributors, system integrators, and online platforms. Indirect sales enable small and medium-sized enterprises to access PC-based automation solutions more conveniently. The availability of pre-configured packages, localized support, and flexible financing options through distributors enhances the adoption of indirect sales channels across emerging markets.

• By Industry

On the basis of industry, the PC-based automation market is segmented into discrete industry and process industry. The discrete industry segment dominated the largest market revenue share in 2024, driven by extensive automation adoption in manufacturing sectors such as automotive, electronics, and machinery. Discrete industries rely on PC-based automation for precision, productivity, and efficient assembly-line operations. The ability to customize solutions for varying product lines and manage complex workflows reinforces the dominance of this segment.

The process industry segment is anticipated to witness the fastest growth rate from 2025 to 2032, fueled by increasing automation needs in chemicals, oil and gas, pharmaceuticals, and food and beverage sectors. Process industries benefit from PC-based automation in monitoring continuous production processes, ensuring quality control, and minimizing operational downtime. Growing focus on process optimization, energy efficiency, and regulatory compliance is driving the adoption of advanced automation solutions in this segment.

Personal Computer (PC)-Based Automation Market Regional Analysis

• North America dominated the personal computer (PC)-based automation market with the largest revenue share in 2024, driven by widespread adoption of industrial automation and advanced manufacturing technologies
• Industries in the region are increasingly investing in PC-based automation for real-time monitoring, process optimization, and integration with IoT and Industry 4.0 initiatives
• The region’s technologically advanced infrastructure, high industrial automation maturity, and strong focus on productivity improvements are fueling demand. In addition, North American manufacturers prioritize scalable, high-performance solutions, making PC-based automation systems a preferred choice across discrete and process industries

U.S. PC-Based Automation Market Insight

The U.S. PC-based automation market captured the largest revenue share in 2024 within North America, supported by a growing emphasis on smart manufacturing, predictive maintenance, and automation-driven operational efficiency. Adoption is driven by manufacturers seeking to enhance production reliability and reduce downtime through advanced control systems. The increasing integration of industrial PCs, PLCs, and SCADA systems with software solutions for real-time analytics and cloud connectivity is further propelling market growth. Moreover, U.S. companies’ investments in upgrading legacy automation systems and implementing digital transformation initiatives are accelerating market expansion.

Europe PC-Based Automation Market Insight

The Europe PC-based automation market is projected to expand at a substantial CAGR throughout the forecast period, driven by industrial modernization, stringent safety and efficiency regulations, and rising adoption of Industry 4.0 technologies. Countries such as Germany, France, and Italy are witnessing strong demand for PC-based automation across automotive, electronics, and machinery sectors. European industries are increasingly investing in integrated hardware and software solutions to optimize production workflows, improve energy efficiency, and maintain competitiveness. The trend toward smart factories and connected industrial environments is further supporting market growth.

U.K. PC-Based Automation Market Insight

The U.K. PC-based automation market is anticipated to grow at a noteworthy CAGR during the forecast period, fueled by investments in industrial digitalization, automation modernization projects, and a rising focus on production efficiency. Discrete and process industries are adopting PC-based solutions to enhance monitoring, control, and analytics capabilities. Government initiatives supporting smart manufacturing and technological innovation, alongside the country’s strong manufacturing and process industries, are expected to sustain market growth.

Germany PC-Based Automation Market Insight

The Germany PC-based automation market is expected to expand at a considerable CAGR during the forecast period, driven by the country’s well-developed industrial sector, high adoption of smart manufacturing practices, and focus on automation efficiency. German manufacturers prioritize advanced PC-based solutions to maintain competitive advantage, improve productivity, and comply with stringent regulatory standards. Integration of PLCs, industrial PCs, and SCADA systems with cloud and IoT technologies is increasingly prevalent, reinforcing Germany’s position as a key regional market.

Asia-Pacific PC-Based Automation Market Insight

The Asia-Pacific PC-based automation market is poised to grow at the fastest CAGR during the forecast period of 2025 to 2032, fueled by rapid industrialization, urbanization, and rising adoption of automation technologies in countries such as China, Japan, and India. Growing manufacturing activities, focus on smart factories, and government initiatives promoting Industry 4.0 adoption are driving demand for PC-based automation. Increasing investments in modern infrastructure and the expansion of industrial electronics manufacturing hubs in the region are further accelerating market growth.

Japan PC-Based Automation Market Insight

The Japan PC-based automation market is gaining momentum due to the country’s technologically advanced industrial landscape, high precision manufacturing requirements, and demand for process efficiency. Japanese industries are integrating industrial PCs, HMIs, and SCADA systems with automation software for enhanced real-time monitoring and predictive maintenance. The trend toward smart manufacturing and connected production environments, along with an aging workforce requiring simplified automation solutions, is further boosting adoption.

China PC-Based Automation Market Insight

The China PC-based automation market accounted for the largest revenue share in Asia-Pacific in 2024, driven by the country’s rapid industrial expansion, urbanization, and strong manufacturing base. The push toward smart factories, digital transformation, and Industry 4.0 adoption is increasing demand for PC-based automation solutions. China’s growing focus on high-precision, high-efficiency manufacturing, supported by domestic automation technology providers, is propelling the market across discrete and process industries.

Personal Computer (PC)-Based Automation Market Share

The personal computer (PC)-based automation industry is primarily led by well-established companies, including:

• ABB (Switzerland)
• Advantech Co., Ltd. (Taiwan)
• Emerson Electric Co. (U.S.)
• General Electric (U.S.)
• Honeywell International Inc. (U.S.)
• Kontron (Germany)
• Mitsubishi Electric Corporation (Japan)
• OMRON Corporation (Japan)
• Robert Bosch GmbH (Germany)
• Schneider Electric (France)
• Siemens (Germany)
• SCADAfence (Israel)
• Bosch Rexroth AG (Germany)
• IDEC Corporation (Japan)
• Beckhoff Automation (Germany)
• Yokogawa Electric Corporation (Japan)
• Rockwell Automation, Inc. (U.S.)

Latest Developments in Global Personal Computer (PC)-Based Automation Market

• In October 2021, Schneider Electric launched EcoStruxure Automation Expert Version 21.2, expanding its capabilities to manage the full automation lifecycle of water and wastewater operations. This update provides tailored automation, monitoring, and control solutions for water and wastewater sectors, addressing operational challenges while improving efficiency and sustainability. By enabling comprehensive lifecycle management, it allows industries to reduce downtime, optimize resource usage, and integrate advanced analytics into existing systems. The development reinforces the trend toward sector-specific PC-based automation solutions that enhance productivity, reduce operational costs, and support environmental compliance, marking a significant step in specialized industrial automation adoption
• In November 2020, Schneider Electric introduced EcoStruxure Automation Expert Version 21.0, a software-centric automation system enhancing interoperability across industrial applications. The system breaks down technology silos by providing a universal framework for seamless integration and scalability. Its plug-and-produce approach simplifies system deployment, reduces implementation time, and ensures safe, reliable operations. By advancing software-centric automation, it allows manufacturers to optimize processes, increase operational efficiency, and respond flexibly to evolving production demands, strengthening digitalization across diverse industrial sectors
• In February 2020, Beckhoff Automation introduced innovative technologies for material handling and intralogistics, including the EP7402 controller, TwinCAT/BSD alternative operating system PC-based controllers, and the ultra-compact C6025 Industrial PC. These solutions enhance automation and efficiency in material handling processes, supporting optimized conveyor operations and flexible intralogistics workflows. By combining high-performance processing, compact design, and scalable software integration, Beckhoff’s offerings enable businesses to improve throughput, reduce downtime, and manage complex logistics operations effectively. This reflects the growing demand for versatile, high-performance PC-based automation systems in industrial logistics
• In February 2020, SICK unveiled the SIG200 ProfiNet Sensor Integration Gateway, designed to seamlessly integrate sensor data into higher-level systems. The SIG200 improves data transparency and facilitates smoother communication between sensors and networked systems, enhancing operational efficiency and real-time data management. Its capabilities allow industries to streamline processes, reduce errors, and achieve better visibility into production and logistics operations. By enabling smarter decision-making and connectivity, this gateway has accelerated the adoption of intelligent PC-based automation solutions across multiple industrial sectors
• In January 2020, Siemens launched the SINUMERIK ONE digital native CNC system, integrating a digital twin with the CNC controller for advanced machine tool control. The SINUMERIK ONE enables virtual commissioning and real-time simulation, significantly reducing setup time and accelerating time-to-market for complex machining operations. By combining digital twin technology with real-time control, it improves precision, productivity, and operational efficiency while enabling predictive maintenance. This innovation has been a key driver in the digital transformation of manufacturing, promoting the adoption of intelligent PC-based automation solutions in high-precision industrial applications

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