The global advanced process control (APC) market attained a value of USD 2.03 Billion in 2025 and is projected to expand at a CAGR of 10.70% through 2035. The market is further expected to achieve USD 5.61 Billion by 2035. Digital twin expansion across continuous manufacturing lines is elevating APC integration as firms seek real-time optimization and autonomous plant performance.
Industrial operators are shifting from traditional control frameworks to AI-embedded, model-predictive architectures. In February 2023, 3D computer vision company Coherix introduced AI enabled adaptive process control solutions that deliver continuous in-line process control. This aligns with the broader advanced process control (APC) market trend across North American and European refineries, where majority of the operators reported rising operational instability from volatile feedstock qualities, pushing them toward mass adoption.
Additionally, as industrial plants widen their digital transformation budgets, APC suppliers are building solutions that merge multivariable control, anomaly detection, and optimization layers into single operational stacks. Players such as Yokogawa, ABB, Honeywell, and AspenTech are rolling out domain-specific APC packages, some tuned for ethylene crackers, others for cement kilns or upstream production wells, driving the overall advanced process control (APC) market value. In May 2021, Yokogawa Electric Corporation announced that Yokogawa and Shell have jointly developed Platform for Advanced Control and Estimation R5.03 under the OpreX Asset Operations and Optimization family. This specialization helps operators reduce downtime and maximize consistency in product specs, even when feed conditions drift sharply.
Base Year
Historical Period
Forecast Period
Compound Annual Growth Rate
10.7%
Value in USD Billion
2026-2035
*this image is indicative*
Digital twins are transforming from pilot projects to production-grade control assets, enabling closed-loop APC that uses running plant models to predict and correct process drift. Suppliers are bundling twin creation with MPC tuning services to deliver faster ROI, oil refiners and specialty chemical plants are using twins to compress ramp-up schedules and stabilize product quality. In November 2025, Schneider Electric, AVEVA, and ETAP announced their membership in the Alliance for Open USD (Universal Scene Description), redefining the advanced process control (APC) market dynamics. In several countries, industrial modernization grants and tax incentives are encouraging digital twin pilots inside heavy industry parks, accelerating vendor-client partnerships.
Cloud-native deployment of advanced MPC engines is changing procurement dynamics. Vendors offer SaaS control kernels with on-premises execution nodes for latency-sensitive loops. This hybrid approach is allowing smaller plants to access advanced algorithms without heavy upfront servers or specialized staff, and it is enabling centralized control rooms to standardize APC packages across plant fleets, accelerating the overall advanced process control (APC) market growth. In February 2025, Hexagon's Manufacturing Intelligence division introduced a new cloud-native solution to test, train, and validate Advanced Driver-Assistance Systems (ADAS) and autonomous vehicle systems. Regulators in energy-intensive sectors are also prompting firms toward centralized reporting, which aligns well with cloud-hosted APC stacks that deliver standardized audit trails for compliance and carbon reporting.
A wave of AI-based inferential measurements and virtual analyzers is reducing reliance on slow or costly lab hardware. Vendors are embedding data-driven estimators into APC suites so that operators can control inferred product quality attributes in real time. Governments funding Industry 4.0 pilot programs are supporting joint lab-to-factory projects that validate AI models for inferential concentration and moisture predictions. Qualcomm Technologies, Inc., in January 2025, announced Qualcomm AI On-Prem Appliance Solution, an on-premises desktop or wall-mounted hardware solution, and Qualcomm AI Inference Suite, a set of software and services for AI inferencing spanning from near-edge to cloud, catering to the surging demand in the advanced process control (APC) market.
Energy efficiency audits, emissions reporting, and net-zero commitments are making APC a frontline tool to reduce fuel consumption and process waste. Utilities and heavy manufacturers are being required to show continuous improvement in energy intensity metrics. APC systems tuned for energy-aware optimization are becoming procurement priorities. Vendors are shipping domain-specific energy modules that trade-off output for carbon intensity, enabling companies to meet regulatory targets without full process redesign, reshaping the advanced process control (APC) market value. For example, in February 2024, GE Vernova unveiled new AI-based software to advance industrial sustainability and operations goals simultaneously.
APC suppliers are offering verticalized, pre-configured control stacks for crackers, kilns, pulp digesters and other asset classes in place of generic toolboxes. These packages include tested MPC templates, recommended inferential models, and supplier-verified tuning parameters, reducing engineering time and risk. In January 2024, ABB launched its technology solution for the cold block stage of the brewing process to further support breweries in their operational efficiency and in the adoption of digital solutions, accelerating the advanced process control (APC) market revenue. Government-sponsored testbeds in manufacturing clusters are helping to validate these modular builds, accelerating adoption among mid-sized operators who lacked the resources for customized APC.
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The EMR’s report titled “Global Advanced Process Control (APC) Market Report and Forecast 2026-2035” offers a detailed analysis of the market based on the following segments:
Market Breakup by Type
Key Insight: Model Predictive Control, Advanced Regulatory Control and inferential control solutions each play discrete roles in augmenting market growth. MPC is dominant in the advanced process control (APC) market for multivariable constraint handling and output optimization. ARC is rapidly growing its shares in the market as firms shore up loop stability and reduce excursions, whereas inferential, sequential, and compressor control modules provide the specialized measures needed for product-quality control and equipment protection.
Market Breakup by End-User Vertical
Key Insight: End user categories considered in the market report include petrochemical, food & beverage, energy and power, oil & gas, pharmaceutical and chemical sectors. Petrochemical plants are prioritizing higher yields and debottlenecking, while food and beverage processors push for tighter batch consistency and fewer product recalls, driving the advanced process control (APC) market value. Power and energy operators focus heavily on fuel efficiency and overall plant availability. Pharmaceutical manufacturers require validated inferential controls to maintain quality and satisfy strict compliance demands, and chemical producers look for more precise molar and thermal control for exact product specifications.
Market Breakup by Region
Key Insight: The advanced process control (APC) market shows distinct regional demand variations. North America sustains its dominance with retrofit budgets, managed services and early standardization. Europe follows closely with strong sustainability targets and regulatory pressures. Asia Pacific is the fastest-growing region driven by greenfield builds and public industrial policy. Latin America and Middle East and Africa are seeing selective investments tied to resource processing and utilities modernization.
By type, Model Predictive Control secures the largest share of the market due to multivariable optimization benefits
Model Predictive Control (MPC) remains the growth engine of the market because it handles multivariable constraints and predictive setpoint management. Vendors are differentiating their MPC by adding faster identification routines, adaptive horizons and built-in soft constraints that let petrochemical plants retain higher output without violating product specifics. In June 2021, Garrett Motion Inc. Announced that it has launched a new software solution focused on Model-Based Predictive Control (MPC) technology with Hyundai Motor Company (HMC). MPC value propositions are typically cited in procurement as reduced off-spec production and fewer manual interventions during feedstock swings.
Advanced Regulatory Control (ARC) also contributes to the growth of the advanced process control (APC) market because plants need robust loop performance before adding higher layers like MPC or inferential estimators. ARC suites now incorporate auto-tuning, nonlinear compensation and embedded diagnostics to keep critical PID loops stable under feed changes and fouling. Vendors are offering ARC as a subscription service with continuous loop health reporting and remote loop specialists, lowering the skill barrier for mid-sized operators.
By end user, the petrochemical sector leads the APC adoption owing to strict quality and output
Petrochemical facilities lead APC adoption since small variations in yield or composition translate into substantial financial gains or losses. APC vendors are building cracker-, reformer- and polymer-grade MPC templates with domain-tested constraints and recommended inferential analyzers. In November 2025, Hitachi launched AI-assisted predictive maintenance service for petrochemical plants. Procurement teams in large petrochemical operators often buy APC as part of debottlenecking or energy-efficiency programs and internal engineering teams prefer vendor-provided tuning sprints to reduce commissioning time.
As per the advanced process control (APC) market report, food and beverage is the fastest-growing end-user category because manufacturers are seeking consistent product quality, lower waste, and energy savings without large capital redesigns. APC for the food and beverage industry is being specialized to manage batch-to-batch variability, ingredient quality drift, and sanitary constraints. Vendors now supply recipe-aware MPC and inferential tools for moisture and texture attributes.
North America accounts for the largest share of the market driven by retrofit budgets and digital maturity
North America leads APC deployment owing to high digital maturity, available retrofit budgets, and a sizeable base of brownfield assets needing performance uplift. Vendors are running regional centers offering managed MPC-as-a-service and remote tuning to support distributed plant portfolios. Public incentives for decarbonization and state-level energy efficiency programs are prompting industrial operators to adopt APC modules that explicitly target energy intensity metrics.
The advanced process control (APC) market in Asia Pacific is rapidly expanding its share in the global market with rapid industrial expansion, new greenfield petrochemical complexes and government programs for smart manufacturing. Large state-backed projects in China, India and Southeast Asia are integrating APC into initial plant design rather than retrofitting, shortening deployment cycles and lowering costs.
Advanced process control (APC) companies are now focusing heavily on reducing commissioning time, offering remote tuning centers, and packaging APC with lifecycle service contracts. These strategies align well with end-user demand for predictable ROI and reduced downtime, especially in petrochemicals, energy, and pharmaceutical sectors. A key opportunity emerging for APC suppliers is the shift toward sustainability-linked optimization, where industrial plants seek control loops to balance output, emissions, and energy intensity in real time.
Advanced process control (APC) market players are investing in digital twins, autonomous loop monitoring, and domain-trained analytics to gain large multi-site deals. Collaborations with cloud hyperscalers and equipment OEMs are expanding the market footprint and enabling APC providers to secure stronger positions in global greenfield and upgrade projects.
ABB Ltd, established in 1988 and headquartered in Zurich, delivers APC solutions deeply integrated with its distributed control systems. The firm focuses on hybrid MPC engines, digital twins, and energy optimization libraries designed specifically for refining, chemicals, and metals plants.
Emerson Electric Co., founded in 1890 and headquartered in Missouri, United States, provides APC through its DeltaV and Ovation platforms, offering advanced predictive control, real-time analytics, and AI-based inferential measurement tools. Emerson serves industries that require high reliability, including power, LNG, and pharmaceuticals. The company emphasizes “closed-loop reliability programs” where APC is bundled with risk monitoring and performance services.
General Electric Company, established in 1892 and headquartered in the United States offers APC capabilities within its industrial software and energy platforms. GE’s focus is on turbine optimization, power plant heat-rate improvement, and predictive combustion control enabled through digital twins.
Schneider Electric SE, founded in 1836 and headquartered in France, delivers APC through its EcoStruxure suite, with a strong focus on sustainability-linked optimization and real-time operations intelligence. Schneider’s APC roadmap centers on AI-enhanced inferential models, autonomous loop supervision, and analytics-driven controller tuning.
*Please note that this is only a partial list; the complete list of key players is available in the full report. Additionally, the list of key players can be customized to better suit your needs.*
Other key players in the market include Siemens AG, among others.
Unlock the latest insights with our advanced process control (APC) market trends 2026 report. Discover regional growth patterns, consumer preferences, and key industry players. Stay ahead of competition with trusted data and expert analysis. Download your free sample report today and drive informed decisions in the market.
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*While we strive to always give you current and accurate information, the numbers depicted on the website are indicative and may differ from the actual numbers in the main report. At Expert Market Research, we aim to bring you the latest insights and trends in the market. Using our analyses and forecasts, stakeholders can understand the market dynamics, navigate challenges, and capitalize on opportunities to make data-driven strategic decisions.*
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In 2025, the market reached an approximate value of USD 2.03 Billion.
The market is projected to grow at a CAGR of 10.70% between 2026 and 2035.
The market is estimated to witness a healthy growth in the forecast period of 2026-2035 to reach USD 5.61 Billion by 2035.
Key strategies driving the market include strengthening cross-industry templates, expanding remote tuning centers, integrating APC with sustainability dashboards, forming OEM partnerships, and delivering modular subscription models that reduce risk and accelerate customer onboarding.
The growing emphasis of end-use sectors such as petrochemical and nuclear power on process safety, improvement, and optimisation and increasing demand for automation solutions across various industries are the key industry trends propelling the market's growth.
The major regions in the market are North America, Latin America, the Middle East and Africa, Europe, and the Asia Pacific.
The different types of APC in the market are predictive model control, advanced regulatory control, inferential, sequential, and compressor control.
The end-user verticals of the market are petrochemical, food and beverage, energy and power, oil and gas, pharmaceutical, and chemical, among others.
The key players in the market include ABB Ltd, Emerson Electric Co., General Electric Company, Schneider Electric SE, and Siemens AG, among others.
APC vendors face challenges like long deployment cycles, model maintenance complexity, talent shortages in process engineering, cybersecurity constraints, and customer hesitation toward cloud-hosted optimization for mission-critical operations.
Explore our key highlights of the report and gain a concise overview of key findings, trends, and actionable insights that will empower your strategic decisions.
| REPORT FEATURES | DETAILS |
| Base Year | 2025 |
| Historical Period | 2019-2025 |
| Forecast Period | 2026-2035 |
| Scope of the Report |
Historical and Forecast Trends, Industry Drivers and Constraints, Historical and Forecast Market Analysis by Segment:
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| Breakup by Type |
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| Breakup by End-User Vertical |
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| Breakup by Region |
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| Market Dynamics |
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| Competitive Landscape |
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| Companies Covered |
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| Report Price and Purchase Option | Explore our purchase options that are best suited to your resources and industry needs. |
| Delivery Format | Delivered as an attached PDF and Excel through email, with an option of receiving an editable PPT, according to the purchase option. |
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