Safety Programmable Controllers Market Report 2025

This report covers market characteristics, size and growth, segmentation, regional and country breakdowns, competitive landscape, market shares, trends and strategies for this market. It traces the market’s historic and forecast market growth by geography.

The safety programmable controllers market size has grown strongly in recent years. It will grow from $5.47 billion in 2024 to $5.78 billion in 2025 at a compound annual growth rate (CAGR) of 5.8%. The growth in the historic period can be attributed to the increasing incidents of industrial accidents, increasing focus on risk management, focus on worker safety, industrial growth in emerging markets, increasing complexity of industrial processes.

The safety programmable controllers market size is expected to see strong growth in the next few years. It will grow to $7.14 billion in 2029 at a compound annual growth rate (CAGR) of 5.4%. The growth in the forecast period can be attributed to the increasing adoption of automation systems, growing adoption of 5G network infrastructure, rising trend of industrial IoT (IoT), growing adoption of industry 4.0, high demand for PLCs form various end-use industries. Major trends in the forecast period include technological advancements, integration of safety features, focus on functional safety standards, industry 4 and IoT integration.

The growing adoption of automation systems is expected to drive the expansion of the safety programmable controller market. An automation system is a combination of hardware and software that functions together to automate tasks or operations that would typically require human intervention. The rising demand for automation systems is fueled by the need for improved quality, scalability, and efficiency. Safety programmable controllers automate safety-related functions such as emergency shutdowns, fault detection, and machine guarding, reducing the need for constant human oversight and enhancing efficiency. This leads to greater output levels and optimized resource use for businesses. For example, in October 2022, the International Federation of Robotics, a Germany-based non-profit organization, reported the installation of 517,385 new industrial robots globally, marking a 31% year-over-year growth rate. As a result, the increasing adoption of automation systems is contributing to the growth of the safety programmable controller market.

Prominent companies in the safety programmable controller market are actively developing advanced automation controllers equipped with advanced information and safety control features to gain a competitive advantage. Advanced automation controllers are sophisticated computing devices deployed in industrial automation systems to manage and monitor diverse processes and machinery. For instance, in April 2023, Omron, a Japan-based electronics company, introduced NX502 automation controllers featuring advanced information control and safety control functionalities. These controllers are engineered to support high production quality and enhance energy productivity. They enable real-time analysis of production data, facilitate process modularization, and provide comprehensive safety control capabilities at large scales and high speeds. Such capabilities contribute to waste reduction, improved energy efficiency, and enhanced production efficiency across various industries.

In February 2023, HIMA, a Germany-based provider of automated solutions, completed the acquisition of Sella Controls in an undisclosed transaction. This strategic acquisition is aimed at expanding the product and service portfolio for railway and process industries, fostering international growth synergies, and bolstering the competitiveness of the HIMA Group. Both companies maintain a focus on safety-related automation, control solutions, and the digitalization of functional safety. Sella Controls, based in the UK, specializes in manufacturing safety programmable controllers, thus complementing HIMA's expertise in safety-related automation solutions.

Major companies operating in the safety programmable controllers market report are Siemens AG; General Electric Company; Mitsubishi Electric Corporation; Schneider Electric SE; Honeywell International Inc.; ABB Group; Eaton Corporation; Emerson Electric Co.; Rockwell Automation; Bosch Rexroth AG; Fuji Electric Co. Ltd.; Omron Corporation; Keyence Corporation; Phoenix Contact GmbH & Co. KG; Yokogawa Electric Corporation; Sick AG; Advantech Co. Ltd.; WAGO; Beckhoff Automation GmbH & Co. KG; Hans Turck GmbH & Co. KG; B&R Industrial Automation GmbH; Banner Engineering Corp.; IDEC Corporation; Pilz GmbH & Co. KG; Leuze electronic Pvt. Ltd.; Treotham Automation Pty Ltd.

North America was the largest region in the safety programmable market in 2024. North America is expected to be the fastest-growing region in the forecast period. The regions covered in the safety programmable controllers market report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East, Africa. The countries covered in the safety programmable controllers market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

The safety programmable controllers market consists of revenues earned by entities by providing services such as safety logic, fault tolerance, safe communication, monitoring and diagnostics, flexibility, and programmability. The market value includes the value of related goods sold by the service provider or included within the service offering. The safety programmable controllers market includes sales of redundant processors, safety communication protocols, and safety memory modules. Values in this market are ‘factory gate’ values, that is, the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors, and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD, unless otherwise specified).

Safety programmable controllers, also referred to as safety PLCs (programmable logic controllers), are specialized devices meticulously crafted to guarantee the secure operation of machinery and industrial processes. These controllers offer diagnostic functionalities, enabling operators to monitor the status of safety devices, diagnose issues, and conduct preventive maintenance to uphold ongoing safety compliance.

The primary types of safety programmable controllers encompass modular, compact, and various other configurations. Modular controllers feature a design that allows for the assembly of customized systems by integrating interchangeable modules, facilitating scalability and tailored solutions to cater to diverse safety requirements. These controllers utilize various technologies, including traditional, safety, and hybrid approaches, and find application across a spectrum of industries such as automotive, oil and gas, energy and power, pharmaceuticals, among others.

The safety programmable controllers market research report is one of a series of new reports that provides safety programmable controllers market statistics, including safety programmable controllers industry global market size, regional shares, competitors with safety programmable controllers market share, detailed safety programmable controllers market segments, market trends, and opportunities, and any further data you may need to thrive in the safety programmable controllers industry. This safety programmable controllers market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenarios of the industry.

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

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