GITNUXREPORT 2025

Process Control Statistics

Global process control market to reach $76.3 billion by 2026.

Jannik Linder

Co-Founder of Gitnux, specialized in content and tech since 2016.

First published: April 29, 2025

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Statistic 1

About 60% of process control data is underutilized due to inadequate analytics tools

Statistic 2

Around 70% of industries have experienced at least one cyber-security breach affecting their process control systems

Statistic 3

Around 35% of process control systems are still using legacy technologies that are more vulnerable to cyber attacks

Statistic 4

Incorporating real-time process data into business decision-making improves operational efficiency by 15-20%, according to industry reports

Statistic 5

65% of process control system developers now prioritize cybersecurity features, reflecting increased awareness of cyber threats

Statistic 6

Process automation can reduce operational costs by up to 22%

Statistic 7

The chemical manufacturing sector utilizes over 55% of the world's process control systems

Statistic 8

The use of predictive analytics in process control can reduce energy consumption by up to 10%

Statistic 9

Predictive maintenance enabled by process control data can extend equipment lifespan by 20-30%

Statistic 10

Energy-efficient process control practices can reduce overall energy use by up to 10%, leading to substantial cost savings

Statistic 11

The integration of blockchain technology with process control enhances traceability and security in supply chains, especially in food and pharma sectors

Statistic 12

Process control system upgrades can reduce energy consumption by 12-15%, leading to significant operational cost savings

Statistic 13

The use of Machine Learning in process control systems is anticipated to grow at a CAGR of over 22% through 2027

Statistic 14

The use of bio-process control systems is expected to grow at a CAGR of 9% through 2025, driven by biopharma and biotech sectors

Statistic 15

The pharmaceutical industry is expected to increase its investment in process automation by 10% annually over the next five years

Statistic 16

The median age of existing process control systems is approximately 15 years, prompting upgrades and replacements in 70% of plants

Statistic 17

Process Control and Automation market is projected to grow at a CAGR of 7.2% from 2022 to 2030

Statistic 18

Industrial robots, which are part of advanced process automation, are projected to grow at a CAGR of 10% through 2028

Statistic 19

The global process automation market is expected to reach $132.65 billion by 2027, with a compound annual growth rate of 6.9%

Statistic 20

The use of cloud-based process control systems is increasing at an annual rate of approximately 20%, facilitating remote management

Statistic 21

The global smart instrumentation market, including process sensors and controllers, is projected to reach $45 billion by 2025, with a CAGR of 8%

Statistic 22

The global demand for process control components such as valves, sensors, and controllers is expected to grow by 7% annually until 2030

Statistic 23

The global process control systems market is expected to reach $76.3 billion by 2026

Statistic 24

The oil and gas industry accounts for approximately 40% of the global process control systems market share

Statistic 25

Distributed Control Systems (DCS) are estimated to hold over 45% of the process control systems market share

Statistic 26

The global market for SCADA systems, integral to process control, is valued at approximately $13 billion in 2023 and is expected to grow steadily

Statistic 27

The automotive industry invests over $2 billion annually in process automation technology, significantly improving production line efficiency

Statistic 28

Over 60% of process control failures are attributed to human error or configuration mistakes

Statistic 29

Process control systems can improve product quality by up to 15%

Statistic 30

The integration of IoT with process control systems can reduce downtime by nearly 25%

Statistic 31

The adoption of cyber-physical systems in process control can increase efficiency by 20-30%

Statistic 32

Automation in food processing plants increases throughput by up to 30%

Statistic 33

The median lifespan of traditional process control components is around 10-15 years, necessitating updates or replacements

Statistic 34

Improving process control in chemical manufacturing can reduce emissions by up to 15%, contributing to environmental compliance

Statistic 35

Approximately 50% of process control system outages are caused by equipment failure, highlighting the importance of predictive maintenance

Statistic 36

Failures in process control systems can result in product recalls, costing companies up to $10 million per incident in the chemical industry

Statistic 37

Process control training and personnel development are linked to a 30% decrease in process failures, according to industry studies

Statistic 38

Advanced analytics and machine learning can detect process anomalies up to 50% faster than traditional methods, improving safety and quality

Statistic 39

The use of predictive analytics in process industries has led to a 12% reduction in unplanned downtime, enhancing overall productivity

Statistic 40

Environmental compliance costs for chemical manufacturers have decreased by roughly 8% due to better process monitoring and control

Statistic 41

In the renewable energy sector, process control systems contribute to a 20% increase in operational reliability

Statistic 42

The deployment of edge computing in process control enhances data processing speed by up to 50%, enabling real-time response

Statistic 43

The automation of wastewater treatment plants using process control systems has improved treatment efficiency by 25%, reducing environmental footprint

Statistic 44

Around 85% of manufacturing companies utilize some form of automation in their processes

Statistic 45

The adoption rate of Industry 4.0 technologies, including process control, is projected to grow at a CAGR of 16.8% from 2021 to 2028

Statistic 46

The implementation of digital twin technology in process control can lead to 20-25% reduction in maintenance costs

Statistic 47

Approximately 90% of process control systems are now Ethernet-based, enhancing connectivity and data sharing

Statistic 48

The use of real-time data analytics in process control can reduce reaction times for operational issues from hours to minutes

Statistic 49

The adoption of advanced process control (APC) techniques can improve yield by up to 12% in semiconductor manufacturing

Statistic 50

Nearly 65% of process control systems are now integrated with enterprise resource planning (ERP) systems to enhance workflow

Statistic 51

The integration of artificial intelligence into process control systems can lead to a 15% increase in process efficiency

Statistic 52

Over 80% of new industrial plants incorporate digital control systems during construction, emphasizing digital transformation in process control

Statistic 53

The adoption of wireless sensor networks in process control can decrease installation costs by 20-25%, with improved scalability

Statistic 54

Approximately 55% of manufacturing process control systems are now monitored and managed remotely, enabling distributed operations

Statistic 55

Over 50% of industrial process control systems still operate on standard PLCs, but migration to more integrated solutions is ongoing rapidly

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Key Highlights

The global process control systems market is expected to reach $76.3 billion by 2026
Around 85% of manufacturing companies utilize some form of automation in their processes
The adoption rate of Industry 4.0 technologies, including process control, is projected to grow at a CAGR of 16.8% from 2021 to 2028
Process automation can reduce operational costs by up to 22%
The oil and gas industry accounts for approximately 40% of the global process control systems market share
Over 60% of process control failures are attributed to human error or configuration mistakes
Distributed Control Systems (DCS) are estimated to hold over 45% of the process control systems market share
The pharmaceutical industry is expected to increase its investment in process automation by 10% annually over the next five years
The median age of existing process control systems is approximately 15 years, prompting upgrades and replacements in 70% of plants
Process control systems can improve product quality by up to 15%
The integration of IoT with process control systems can reduce downtime by nearly 25%
The chemical manufacturing sector utilizes over 55% of the world's process control systems
About 60% of process control data is underutilized due to inadequate analytics tools

As the global process control systems market gears up to reach over $76 billion by 2026, industries worldwide are leveraging automation, IoT, and AI-driven technologies to boost efficiency, reduce costs, and ensure environmental and cybersecurity resilience in an increasingly digital manufacturing landscape.

Data Utilization, Analytics, and Cybersecurity

About 60% of process control data is underutilized due to inadequate analytics tools
Around 70% of industries have experienced at least one cyber-security breach affecting their process control systems
Around 35% of process control systems are still using legacy technologies that are more vulnerable to cyber attacks
Incorporating real-time process data into business decision-making improves operational efficiency by 15-20%, according to industry reports
65% of process control system developers now prioritize cybersecurity features, reflecting increased awareness of cyber threats

Data Utilization, Analytics, and Cybersecurity Interpretation

Despite the pressing need for advanced analytics and cybersecurity, over half of process control data remains underused, legacy systems still pose significant cyber risks, yet integrating real-time insights can boost operational efficiency by up to 20%, highlighting a critical juncture where technological upgrading and security vigilance must converge.

Industry Applications and Sectors

Process automation can reduce operational costs by up to 22%
The chemical manufacturing sector utilizes over 55% of the world's process control systems
The use of predictive analytics in process control can reduce energy consumption by up to 10%
Predictive maintenance enabled by process control data can extend equipment lifespan by 20-30%
Energy-efficient process control practices can reduce overall energy use by up to 10%, leading to substantial cost savings
The integration of blockchain technology with process control enhances traceability and security in supply chains, especially in food and pharma sectors
Process control system upgrades can reduce energy consumption by 12-15%, leading to significant operational cost savings

Industry Applications and Sectors Interpretation

By harnessing advanced process control—and sometimes a touch of blockchain—industries can not only trim operational costs by up to 22% but also extend equipment life, boost energy efficiency, and fortify supply chain security, proving that in the world of industry, smarter control is the ultimate cost-cutting dividend.

Market Growth

The use of Machine Learning in process control systems is anticipated to grow at a CAGR of over 22% through 2027
The use of bio-process control systems is expected to grow at a CAGR of 9% through 2025, driven by biopharma and biotech sectors

Market Growth Interpretation

As machine learning revolutionizes process control with a projected CAGR of over 22% through 2027, while bio-process control, bolstered by biotech and biopharma, advances at a steady 9% through 2025, it's clear that innovation is steering industries toward smarter, more adaptive systems—though perhaps not all at the same pace.

Market Growth and Market Size

The pharmaceutical industry is expected to increase its investment in process automation by 10% annually over the next five years
The median age of existing process control systems is approximately 15 years, prompting upgrades and replacements in 70% of plants
Process Control and Automation market is projected to grow at a CAGR of 7.2% from 2022 to 2030
Industrial robots, which are part of advanced process automation, are projected to grow at a CAGR of 10% through 2028
The global process automation market is expected to reach $132.65 billion by 2027, with a compound annual growth rate of 6.9%
The use of cloud-based process control systems is increasing at an annual rate of approximately 20%, facilitating remote management
The global smart instrumentation market, including process sensors and controllers, is projected to reach $45 billion by 2025, with a CAGR of 8%
The global demand for process control components such as valves, sensors, and controllers is expected to grow by 7% annually until 2030

Market Growth and Market Size Interpretation

As the pharmaceutical industry accelerates its automation investments by 10% annually, coupled with aging systems ripe for upgrades, the booming process control market—which is projected to hit over $132 billion by 2027—signals that embracing cloud-based, smart instrumentation, and robotics is no longer optional but essential for staying ahead in an industry where efficiency and precision are king.

Market Size

The global process control systems market is expected to reach $76.3 billion by 2026
The oil and gas industry accounts for approximately 40% of the global process control systems market share
Distributed Control Systems (DCS) are estimated to hold over 45% of the process control systems market share
The global market for SCADA systems, integral to process control, is valued at approximately $13 billion in 2023 and is expected to grow steadily
The automotive industry invests over $2 billion annually in process automation technology, significantly improving production line efficiency

Market Size Interpretation

With a projected global market exceeding $76 billion by 2026, the dominance of oil and gas—and the pivotal role of DCS and SCADA systems—underscores how industries driving daily life are increasingly orchestrated by sophisticated process control technologies, all while automotive automation accelerates our roads into the future.

System Performance, Reliability, and Failures

Over 60% of process control failures are attributed to human error or configuration mistakes
Process control systems can improve product quality by up to 15%
The integration of IoT with process control systems can reduce downtime by nearly 25%
The adoption of cyber-physical systems in process control can increase efficiency by 20-30%
Automation in food processing plants increases throughput by up to 30%
The median lifespan of traditional process control components is around 10-15 years, necessitating updates or replacements
Improving process control in chemical manufacturing can reduce emissions by up to 15%, contributing to environmental compliance
Approximately 50% of process control system outages are caused by equipment failure, highlighting the importance of predictive maintenance
Failures in process control systems can result in product recalls, costing companies up to $10 million per incident in the chemical industry
Process control training and personnel development are linked to a 30% decrease in process failures, according to industry studies
Advanced analytics and machine learning can detect process anomalies up to 50% faster than traditional methods, improving safety and quality
The use of predictive analytics in process industries has led to a 12% reduction in unplanned downtime, enhancing overall productivity
Environmental compliance costs for chemical manufacturers have decreased by roughly 8% due to better process monitoring and control
In the renewable energy sector, process control systems contribute to a 20% increase in operational reliability
The deployment of edge computing in process control enhances data processing speed by up to 50%, enabling real-time response
The automation of wastewater treatment plants using process control systems has improved treatment efficiency by 25%, reducing environmental footprint

System Performance, Reliability, and Failures Interpretation

Given that over 60% of process control failures stem from human error or misconfigurations, yet automation and advanced analytics can slash downtime by nearly 25% and enhance product quality by 15%—all while reducing emissions and operational costs—it's clear that investing in smarter, more resilient process control systems isn't just a technical upgrade but a strategic necessity for sustainability, safety, and profitability.

Technology Adoption and Innovation

Around 85% of manufacturing companies utilize some form of automation in their processes
The adoption rate of Industry 4.0 technologies, including process control, is projected to grow at a CAGR of 16.8% from 2021 to 2028
The implementation of digital twin technology in process control can lead to 20-25% reduction in maintenance costs
Approximately 90% of process control systems are now Ethernet-based, enhancing connectivity and data sharing
The use of real-time data analytics in process control can reduce reaction times for operational issues from hours to minutes
The adoption of advanced process control (APC) techniques can improve yield by up to 12% in semiconductor manufacturing
Nearly 65% of process control systems are now integrated with enterprise resource planning (ERP) systems to enhance workflow
The integration of artificial intelligence into process control systems can lead to a 15% increase in process efficiency
Over 80% of new industrial plants incorporate digital control systems during construction, emphasizing digital transformation in process control
The adoption of wireless sensor networks in process control can decrease installation costs by 20-25%, with improved scalability
Approximately 55% of manufacturing process control systems are now monitored and managed remotely, enabling distributed operations
Over 50% of industrial process control systems still operate on standard PLCs, but migration to more integrated solutions is ongoing rapidly

Technology Adoption and Innovation Interpretation

As Industry 4.0 transforms manufacturing into a digital symphony, companies harness automation, AI, and connectivity—while still juggling legacy PLCs—illustrating that embracing smart process control is no longer optional but essential for staying ahead in the fast-paced factory realm.