Global Modular PLC Market Growth, Share, Size, Trends and Forecast (2025 - 2031)

• In April 2023, Rockwell Automation expanded its modular PLC offerings with advanced cybersecurity features, providing companies in critical infrastructure sectors with enhanced protection against cyber threats while ensuring seamless operation.

• In September 2020, Siemens launched a new series of modular PLC systems that offer enhanced scalability, flexibility, and ease of integration, aimed at industries like manufacturing and automotive for precise control applications.

The Global Modular PLC Market is diverse, with segmentation based on type, end-user industry and communication protocol. Each segment plays a crucial role in the overall market dynamics and caters to different industrial requirements.

Modular PLCs are preferred over compact PLCs due to their scalability and flexibility. Modular PLCs allow users to expand and customize their automation systems by adding or removing modules as needed, making them ideal for complex industrial processes that require frequent modifications.

The automotive sector is a significant consumer of modular PLCs, driven by the need for automation in manufacturing and assembly lines. The food and beverage industry also represents a substantial share, with modular PLCs used to ensure precision and quality control in production processes. The energy and power sector utilizes PLCs for grid management and renewable energy integration, while the pharmaceutical industry relies on automation for compliance with stringent regulatory standards.

The market includes Fieldbus, Industrial Ethernet, and Wireless protocols. Industrial Ethernet is gaining traction due to its high-speed data transfer capabilities and reliability, making it suitable for real-time control applications. Wireless communication is also emerging as a viable option, providing flexibility and ease of installation in remote or hard-to-reach locations.

Global Modular PLC Segment Analysis

In this report, the Global Modular PLC Market has been segmented by Type, End-User Industry, Communication Protocol and Geography.

Global Modular PLC Market, Segmentation by Type

Compact PLCs and modular PLCs represent two distinct approaches to programmable logic controllers (PLCs), each catering to specific industrial automation needs based on their design and functionality.

Compact PLCs are characterized by their integrated design, where the CPU (Central Processing Unit), power supply, and I/O (Input/Output) modules are housed within a single unit. This integrated approach offers simplicity and compactness, making compact PLCs ideal for applications where space is limited and fewer I/O points are required. They are commonly used in small-scale automation tasks where cost-effectiveness and ease of installation are crucial. Compact PLCs are known for their reliability and straightforward operation, making them suitable for environments with less complex automation needs.

Modular PLCs, on the other hand, feature a modular architecture with separate modules for the CPU, power supply, and I/O. This modular design allows users to customize and expand the PLC system according to specific application requirements. Modular PLCs offer greater flexibility and scalability compared to compact PLCs, making them ideal for complex and large-scale automation applications. Users can add or remove modules as needed, enabling them to adapt the system to changing operational needs or to expand automation capabilities over time. This scalability is particularly beneficial in industries where processes are diverse and evolving, requiring a PLC system that can grow alongside operational demands.While compact PLCs excel in simplicity, cost-efficiency, and space-saving benefits for smaller automation projects, modular PLCs provide the flexibility, scalability, and customization options necessary to meet the demands of more extensive and varied industrial automation applications

While compact PLCs excel in simplicity, cost-efficiency, and space-saving benefits for smaller automation projects, modular PLCs provide the flexibility, scalability, and customization options necessary to meet the demands of more extensive and varied industrial automation applications. The choice between compact and modular PLCs often depends on factors such as the scale of automation required, the complexity of processes, and future expansion plans within the industrial setting.

Global Modular PLC Market, Segmentation by End-User Industry

In the automotive industry, PLCs play a crucial role in enhancing manufacturing and assembly line operations. They are integral to automating processes such as robotic welding, assembly line sequencing, and quality control inspections. By using PLCs, automotive manufacturers achieve higher efficiency and precision in production, ensuring consistent product quality and reducing manufacturing cycle times. PLCs also enable real-time monitoring of production metrics, allowing for immediate adjustments to optimize workflow and minimize downtime.

In the food and beverage sector, PLCs are essential for maintaining stringent quality control standards and ensuring consistency in production processes. PLCs regulate variables such as temperature, pressure, and ingredient proportions with precision, crucial for producing safe and high-quality food products. They facilitate automated batch processing, recipe management, and packaging operations, minimizing human error and product variability. This automation not only improves efficiency but also enhances product traceability and compliance with food safety regulations.

In the energy and power industry, PLCs are used for grid management and the integration of renewable energy sources. PLCs control and monitor complex electrical systems, ensuring stable and efficient distribution of electricity. They manage power generation, transmission, and distribution networks, optimizing energy flow and reducing operational costs. With the increasing adoption of renewable energy sources such as solar and wind, PLCs facilitate the seamless integration of these intermittent energy sources into the grid, balancing supply and demand to maintain grid stability.

In the pharmaceutical sector, PLCs are employed to comply with stringent regulatory standards and ensure precision in manufacturing processes. PLCs control critical parameters in pharmaceutical production, such as dosage accuracy, mixing ratios, and sterilization processes. They enable automated monitoring and documentation of production conditions, ensuring adherence to Good Manufacturing Practices (GMP) and regulatory requirements for product safety and efficacy. PLCs also support batch tracking and serialization, facilitating efficient inventory management and regulatory compliance audits.

Global Modular PLC Market, Segmentation by Communication Protocol

Fieldbus is a widely used network protocol in industrial control systems, facilitating real-time distributed control across manufacturing and process industries. It operates on a master-slave architecture, where a central controller (master) communicates with various devices (slaves) such as sensors, actuators, and PLCs. Fieldbus protocols like PROFIBUS, Modbus, and DeviceNet enable efficient data exchange, allowing for precise monitoring and control of industrial processes. By integrating multiple devices into a single network, Fieldbus optimizes communication, reduces wiring complexity, and enhances system reliability.

Industrial Ethernet represents a newer generation of communication protocols designed to meet the growing demand for high-speed data transfer and reliability in industrial automation. Unlike traditional Ethernet used in office networks, Industrial Ethernet standards such as Ethernet/IP, PROFINET, and EtherCAT prioritize determinism and real-time control capabilities. This makes Industrial Ethernet suitable for applications where rapid data exchange is critical, such as synchronized motion control, machine vision systems, and real-time monitoring of production lines. Its scalability and compatibility with existing Ethernet infrastructure further enhance its adoption across diverse industrial sectors.

Wireless technology has revolutionized industrial automation by offering flexibility and ease of installation, particularly in remote or challenging environments. Wireless protocols like WiFi, Bluetooth, and Zigbee enable connectivity without the constraints of physical cables, facilitating mobile and decentralized control solutions. Wireless networks are ideal for applications requiring mobility, such as automated guided vehicles (AGVs), warehouse logistics, and outdoor monitoring systems. Despite challenges like signal interference and security concerns, advancements in wireless technology continue to expand its role in industrial automation, enabling scalable and cost-effective solutions for modern manufacturing and infrastructure projects.

Global Modular PLC Market, Segmentation by Geography

In this report, the Global Modular PLC Market has been segmented by Geography into five regions; North America, Europe, Asia Pacific, Middle East and Africa and Latin America.

Global Modular PLC Market Share (%), by Geographical Region, 2024

The geographical distribution of the Global Modular PLC Market highlights distinct trends across various regions, reflecting both established leadership and emerging opportunities. North America and Europe dominate the market, primarily due to their advanced industrial infrastructure and early adoption of automation technologies. These regions boast a mature industrial sector with high demand for efficient manufacturing processes and stringent quality standards, driving the uptake of modular PLCs. The presence of major manufacturing industries, including automotive, electronics, and aerospace, further reinforces their market leadership.

In contrast, the Asia-Pacific region is experiencing robust growth in the modular PLC market. Countries like China, Japan, and India are leading this expansion, propelled by rapid industrialization, infrastructure development, and substantial investments in automation. The automotive manufacturing boom in countries like China and India, coupled with increasing adoption of smart manufacturing practices, contributes significantly to market growth. Moreover, initiatives promoting industrial automation and digital transformation are accelerating the deployment of modular PLCs across diverse sectors in the region.

Latin America and the Middle East & Africa regions are emerging as promising markets for modular PLCs. These regions are witnessing significant investments in infrastructure projects and manufacturing facilities, driven by economic diversification efforts and urbanization trends. Government initiatives to enhance industrial productivity and competitiveness are further fueling demand for automation solutions, including modular PLCs. Despite facing challenges such as economic volatility and technological adoption barriers, these regions offer considerable growth opportunities for PLC manufacturers aiming to expand their global footprint.

This report provides an in depth analysis of various factors that impact the dynamics of Global Modular PLC Market. These factors include; Market Drivers, Restraints and Opportunities Analysis.

Drivers, Restraints and Opportunity Analysis

Drivers:

• Increasing adoption of automation in manufacturing industries
• Rising demand for industrial IoT solutions
• Need for improved operational efficiency and productivity
• Growing trend of Industry 4.0

• Advancements in technology and innovation in PLCs - These are crucial drivers of the Global Modular PLC Market. Over recent years, the evolution of PLC technology has been remarkable, with continuous improvements enhancing the performance, reliability, and functionality of these systems. Modern modular PLCs now incorporate advanced features such as high-speed processors, expanded memory capacity, and sophisticated communication protocols, making them more capable of handling complex automation tasks.

  One of the significant technological advancements in PLCs is the integration of artificial intelligence (AI) and machine learning (ML) capabilities. This integration allows PLCs to perform predictive maintenance, optimize processes in real-time, and improve decision-making based on data analytics. For instance, AI-enabled PLCs can predict equipment failures before they occur, reducing downtime and maintenance costs.

  Moreover, innovations in cybersecurity have also enhanced the appeal of modular PLCs. As industrial automation systems become increasingly connected, the risk of cyber threats has escalated. Modern PLCs are now equipped with robust security features, including encryption, secure boot, and authentication protocols, ensuring that the systems are protected against unauthorized access and cyberattacks.

Restraints:

• High initial cost of implementation
• Complexity in integration with existing systems
• Lack of skilled workforce for PLC programming and maintenance
• Limited awareness and adoption in small and medium-sized enterprises (SMEs)

• Concerns regarding cybersecurity threats - These pose a significant restraint to the Global Modular PLC Market. As industries increasingly adopt automation and interconnected systems, the potential for cyberattacks and security breaches has become a major concern. PLCs, being integral components of industrial control systems, are particularly vulnerable to cyber threats due to their connectivity and the critical functions they perform.

  One of the primary concerns is the risk of unauthorized access to PLC systems. Cybercriminals can exploit vulnerabilities in PLC hardware or software to gain control over industrial processes, leading to severe consequences such as operational disruptions, equipment damage, and even safety hazards. For instance, a cyberattack on a PLC controlling a manufacturing line could halt production, cause machinery malfunctions, or result in defective products.

  Another aspect of cybersecurity concerns is the potential for data breaches. PLCs often handle sensitive operational data, including production parameters, machine statuses, and performance metrics. A breach of this data could expose valuable proprietary information, leading to competitive disadvantages and financial losses for the affected companies.

  Additionally, the complexity of securing industrial control systems presents a challenge. Unlike IT systems, which can be regularly updated with the latest security patches, PLCs often operate in environments where downtime is costly and maintenance windows are limited. This makes it difficult to apply security updates promptly, leaving the systems vulnerable to emerging threats.

Opportunities:

• Growth in emerging economies
• Increasing demand for customized and scalable PLC solutions
• Expansion of the renewable energy sector
• Development of advanced and user-friendly programming tools

• Partnerships and collaborations with IoT and AI companies - These present a significant opportunity for the Global Modular PLC Market. As the industrial sector embraces digital transformation, the integration of Internet of Things (IoT) and Artificial Intelligence (AI) technologies with modular PLCs is becoming increasingly important. These partnerships can drive innovation, enhance system capabilities, and open new avenues for growth.

  Collaborating with IoT companies allows PLC manufacturers to incorporate advanced connectivity features into their systems. IoT-enabled PLCs can collect and transmit data from various sensors and devices in real-time, providing valuable insights into industrial processes. This data can be used to optimize operations, improve efficiency, and reduce downtime. For instance, IoT-enabled PLCs can monitor equipment health and predict maintenance needs, preventing unexpected failures and minimizing maintenance costs.

  Moreover, partnerships with AI companies can bring intelligent automation solutions to the forefront. AI algorithms can analyze the data collected by IoT-enabled PLCs to identify patterns and anomalies, enabling predictive maintenance, process optimization, and quality control. For example, AI-driven PLCs can adjust manufacturing parameters in real-time based on data analysis, ensuring consistent product quality and reducing waste.

  These collaborations also facilitate the development of user-friendly interfaces and software tools that simplify the programming and configuration of PLC systems. By leveraging the expertise of IoT and AI companies, PLC manufacturers can create more intuitive and accessible solutions, making it easier for engineers and technicians to deploy and manage automation systems.

Key players in Global Modular PLC Market include:

• Siemens
• Rockwell Automation
• Schneider Electric
• Mitsubishi Electric
• ABB
• Omron Corporation
• Honeywell International
• Bosch Rexroth
• Emerson Electric
• General Electric

In this report, the profile of each market player provides following information:

• Company Overview and Product Portfolio
• Key Developments
• Financial Overview
• Strategies
• Company SWOT Analysis