US Industrial Control & Factory Automation Market Outlook (2025-2035)
The US Industrial Control & Factory Automation Market is experiencing rapid transformation alongside advancements in AI, IoT, and smart manufacturing. Companies are investing in end-to-end automation solutions for adaptability, operational efficiency, and real-time data-driven decision-making. As the industry migrates toward digital factories, integration of edge computing and robotics underpins higher productivity and sustainability. By 2025, the market size is projected to reach USD 46,350 Million, driven by increasing adoption across automotive, pharmaceuticals, and food & beverage sectors, with expanding roles for cloud-enabled analytics and advanced machine learning. The industry is characterized by strong vendor competition, robust regional presence, and emerging opportunities for industrial digitization across all enterprise sizes.
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Latest Market Dynamics
Key Drivers
- Widespread Adoption of Industrial IoT (IIoT) Platforms: The proliferation of IIoT is central to driving factory automation, allowing real-time monitoring and process optimization. For example, Siemens expanded its MindSphere IoT operating system capabilities in 2024, empowering manufacturers to gather deeper plant-floor insights and streamline operations.
- Rising Demand for Energy Efficiency and Sustainability: With surging energy costs and regulatory pressure, automated energy management solutions are in high demand. Schneider Electric, in June 2024, partnered with US-based manufacturers to implement AI-powered sustainability platforms, reducing operational costs and environmental impact.
Key Trends
- Intelligent Predictive Maintenance: The integration of machine learning for predictive maintenance is redefining asset management. In April 2024, Rockwell Automation deployed its FactoryTalk® Analytics in leading US pharma plants, significantly increasing equipment uptime and reducing unplanned outages.
- Edge Computing Deployment: Adoption of edge computing for quick and secure data processing is rising. Emerson Electric Co. introduced a new edge control platform in July 2024, facilitating immediate data utilization in mission-critical production lines.
Key Opportunities
- Expansion of Cloud-Based MES: Shifting to cloud-based Manufacturing Execution Systems (MES) is enhancing scalability and remote visibility. Honeywell International’s cloud MES rollout in Q3 2024 provided automotive OEMs with improved real-time production control and decreased downtime.
- Robotics Integration in Food Processing: Demand for automated handling solutions creates space for robotics adoption. ABB Ltd. partnered with major US food processors in August 2024 for advanced robotics-based quality inspection, improving throughput and safety.
Key Challenges
- Integration Complexity with Legacy Systems: Upgrading older factories poses significant compatibility and reliability issues. General Electric’s 2024 study highlighted that 62% of US SME manufacturers cited legacy integration as their top automation hurdle.
- Cybersecurity Threats: Increasing digitization exposes operations to new cyber risks. Palo Alto Networks and Mitsubishi Electric jointly addressed this by launching bespoke cybersecurity suites for industrial automation in June 2024.
Key Restraints
- High Upfront Capital Expenditure: Many US manufacturers hesitate due to the substantial initial investment in automation technologies. Fanuc Corporation’s survey in May 2024 revealed that 40% of medium-sized factories delayed projects awaiting ROI clarity.
- Workforce Skill Gaps: The need for advanced skills in digital and automation technologies creates staffing issues. Bosch Rexroth AG launched skills training initiatives with US technical colleges in early 2024 to address this industry bottleneck.
Market Share by Type, 2025
The market is led by Programmable Logic Controllers (PLCs) at 28%, closely followed by SCADA systems (25%) and Distributed Control Systems (DCS) at 17%. The dominance of PLCs mirrors their crucial role in discrete automation and broad flexibility across manufacturing segments. SCADA’s strong performance is driven by the sector’s need for scalable, centralized process monitoring. DCS also maintains a substantial share, especially in process-intensive industries like chemicals and energy. The continued investment in advanced MES, HMI, sensors, and robotics further highlight the sector’s shift toward integrated and intelligent control, enabling smart manufacturing environments. In sum, manufacturers’ focus on reliability, modularity, and real-time responsiveness is reflected in the market’s type-wise distribution.
Market Share by Application, 2025
Automotive leads the US Industrial Control & Factory Automation Market applications with a 32% market share, followed by food and beverage at 21% and pharmaceuticals at 15%. Automotive’s dominance is propelled by the sector’s aggressive adoption of robotics and real-time analytics for high-precision manufacturing. Food & beverage automation focuses on quality assurance, traceability, and regulatory compliance, driving advanced automation installations. Pharmaceuticals benefit from stringent process control and traceability, fostering growth in MES and DCS solutions. Other applications—including chemicals, energy & utilities, and various discrete manufacturing—exhibit steady automation penetration as companies prioritize safety, efficiency, and regulatory adherence. Cross-industry digital transformation initiatives will continue to accelerate multi-sector adoption of smart factory technologies.
Market Revenue (USD Million), 2020-2035
The market revenue demonstrates robust growth from USD 28,500 Million in 2020 to an estimated USD 46,350 Million by 2025, further projected to reach USD 93,200 Million in 2035. The steady upward trend reflects accelerating triple-digit investments in digital manufacturing, AI-driven process optimizations, and regulatory tailwinds supporting advanced automation adoption. This growth trajectory underscores the industry’s transition from legacy systems to connected, intelligent automation infrastructures. The compound annual growth rate (CAGR) from 2025 to 2035 stands at approximately 7.2%, powered by increasing demand across diverse end-use sectors and advancements in enabling technologies.
YOY (%) Growth, 2020-2035
Year-on-year growth in the US Industrial Control & Factory Automation Market shows a peak increment between 2023 and 2027 due to surge in large-scale adoption in automotive and energy. The growth rate tops at 10% in 2025, leveling to an average of 7.2% by 2035 as the sector matures. Key factors behind these growth patterns are the increasing acceptance of Industry 4.0 technologies, state incentives for smart factory upgrades, and evolving consumer demand for high-quality products. Sustained YOY gains are anticipated with widespread digitalization and successful integration of AI, Machine Learning, and IoT technologies.
Market Share by Region, 2025
The Midwest region commands the largest share at 35%, attributed to its high concentration of automotive, manufacturing, and food processing industries. The South follows with 28% market share, driven by a robust chemicals and energy sector presence. The Northeast, propelled by technological innovation and pharmaceutical hubs, claims 20%, while the West, known for technology adoption and electronics manufacturing, accounts for 17%. Regional variations are heavily influenced by industrial density, state incentives, and local supply chain capabilities. Enhanced automation initiatives in traditional industrial centers are key to shaping the regional dynamics of the US factory automation market.
Market Share by Players, 2025
Siemens leads the US market with a 19% share, followed by Rockwell Automation (15%) and ABB Ltd. (12%). Emerson Electric, Schneider Electric, and Honeywell collectively account for another 27%, indicating intense competition among multinational OEMs. These top players continue to expand their product offerings, partner with technology firms, and invest in R&D to maintain their leadership. Niche players like Omron, Mitsubishi Electric, and Fanuc contribute through specialization in robotics and advanced control solutions. The highly competitive landscape incentivizes ongoing innovation, customer-centric service models, and integrated automation platforms.
Market Share by Buyers, 2025
Automotive OEMs and Tier 1 parts manufacturers make up 30% of total industry buyers, followed by food and beverage conglomerates at 22%. Pharmaceutical firms account for 12%, while chemicals and energy operators represent another 16%. Various discrete manufacturing and technology sector adopters constitute the remaining 20%. Buyer distribution highlights the critical role of compliance, mass customization, and digital traceability in driving automation investment priorities. Leading buyers demand scalable, interoperable systems capable of supporting digital transformation efforts across diverse manufacturing portfolios in 2025.
Study Coverage
| Metrics | Details |
|---|
| Years | 2020-2035 |
| Base Year | 2025 |
| Market Size | Revenue (USD Million) |
| Regions | Midwest, South, Northeast, West |
| Segments | By Type: SCADA, DCS, PLC, MES, HMI, Sensors, Robotics; By Application: Automotive, Food & Beverage, Pharmaceuticals, Chemicals, Energy & Utilities, Others; By Distribution Channels: Direct, Distributors, Online, System Integrators, Value-Added Resellers, Others; By Technology: IoT, AI, Cloud Computing, Big Data, Machine Learning, Edge Computing; By Organization Size: Small, Medium, Large |
| Players | Siemens AG, ABB Ltd., Rockwell Automation, Emerson Electric Co., Schneider Electric, Honeywell International Inc., Mitsubishi Electric Corporation, General Electric, Yokogawa Electric Corporation, Omron Corporation, Fanuc Corporation, Bosch Rexroth AG, Hitachi Ltd., ABB Baldor, B&R Industrial Automation |
Key Recent Developments
- June 2024: Schneider Electric launched a new AI-embedded energy management suite for US manufacturers, expanding predictive analytics capacities.
- July 2024: Emerson Electric Co. unveiled its Edge Control for industrial automation, enabling rapid data processing at the production floor.
- August 2024: ABB Ltd. collaborated with US-based food processing giants to deploy next-gen robotics-powered quality inspection lines.
- May 2024: Fanuc Corporation announced a milestone in workforce development with major US technical colleges, focusing on robotics skills expansion.
- April 2024: Rockwell Automation rolled out FactoryTalk® Analytics in leading US pharmaceutical plants to elevate predictive maintenance and operational efficiency.
