Virtual PLC and Soft PLC Market Opportunity, Growth Drivers, Industry Trend Analysis, and Forecast 2024 – 2032
The Global Virtual PLC And Soft PLC Market was valued at USD 865 million in 2023, with projections indicating a compound annual growth rate (CAGR) of 13% from 2024 to 2032. The rising adoption of Industry 4.0 technologies is a key factor fueling the demand for Virtual and Soft PLCs. These systems play a crucial role in automating processes, enabling real-time monitoring, and facilitating data analysis within manufacturing settings. As industries undergo digital transformation, Virtual PLCs that integrate with cloud platforms and IoT devices are becoming essential. They support seamless communication and control across various production stages, contributing to the development of smart factories that aim to improve productivity, minimize downtime, and optimize resource utilization through intelligent automation.
The market is segmented by control level type into field level, process level, supervisory level, and enterprise level, with the field level expected to experience a CAGR of over 13% during the forecast period. This segment encompasses the physical layer where sensors, actuators, and other field devices directly interact with machinery and production processes. Virtual and Soft PLCs monitor and control these devices by processing the real-time data they generate. Additionally, the market is categorized by deployment type, including on-premises and cloud-based solutions.
The cloud-based segment is anticipated to reach USD 1 billion by 2032. This segment represents the next generation of Virtual and Soft PLC solutions, where software is hosted on cloud platforms, offering advantages such as scalability, cost-effectiveness, and remote accessibility. Cloud-based PLC systems enable real-time monitoring, control, and analysis from any location, enhancing flexibility for global operations and predictive maintenance. North America Virtual PLC and Soft PLC market held over 35% share in 2023. The United States is a significant contributor to this growth, driven by robust demand in sectors like manufacturing, energy, and automotive for advanced automation technologies. The country leads in the adoption of Industry 4.0, with an increasing implementation of Virtual PLCs in factories to support real-time monitoring, predictive maintenance, and scalable automation solutions.The emphasis on cloud infrastructure and remote operations, particularly in industries such as oil and gas, further propels the reliance on Virtual PLCs for effectively managing complex industrial systems.
The market is segmented by control level type into field level, process level, supervisory level, and enterprise level, with the field level expected to experience a CAGR of over 13% during the forecast period. This segment encompasses the physical layer where sensors, actuators, and other field devices directly interact with machinery and production processes. Virtual and Soft PLCs monitor and control these devices by processing the real-time data they generate. Additionally, the market is categorized by deployment type, including on-premises and cloud-based solutions.
The cloud-based segment is anticipated to reach USD 1 billion by 2032. This segment represents the next generation of Virtual and Soft PLC solutions, where software is hosted on cloud platforms, offering advantages such as scalability, cost-effectiveness, and remote accessibility. Cloud-based PLC systems enable real-time monitoring, control, and analysis from any location, enhancing flexibility for global operations and predictive maintenance. North America Virtual PLC and Soft PLC market held over 35% share in 2023. The United States is a significant contributor to this growth, driven by robust demand in sectors like manufacturing, energy, and automotive for advanced automation technologies. The country leads in the adoption of Industry 4.0, with an increasing implementation of Virtual PLCs in factories to support real-time monitoring, predictive maintenance, and scalable automation solutions.The emphasis on cloud infrastructure and remote operations, particularly in industries such as oil and gas, further propels the reliance on Virtual PLCs for effectively managing complex industrial systems.
Report Content
CHAPTER 1 METHODOLOGY & SCOPE
1.1 Market scope & definitions
1.2 Base estimates & calculations
1.3 Forecast calculations
1.4 Data sources
1.4.1 Primary
1.4.2 Secondary
1.4.2.1 Paid sources
1.4.2.2 Public sources
CHAPTER 2 EXECUTIVE SUMMARY
2.1 Industry synopsis, 2021-2032
Chapter Industry Insights
3.1 Industry ecosystem analysis
3.1.1 Factor affecting the value chain
3.1.2 Profit margin analysis
3.1.3 Disruptions
3.1.4 Future outlook
3.1.5 Manufacturers
3.1.6 Distributors
3.2 Supplier landscape
3.3 Profit margin analysis
3.4 Key news & initiatives
3.5 Regulatory landscape
3.6 Impact forces
3.6.1 Growth drivers
3.6.1.1 Rising adoption of industry 4.0 and smart manufacturing
3.6.1.2 Growing demand for remote monitoring and control
3.6.1.3 Integration with emerging technologies like AI and Edge computing
3.6.1.4 Increased focus on flexibility and scalability
3.6.2 Industry pitfalls & challenges
3.6.2.1 Cybersecurity risks and vulnerabilities
3.6.2.2 High initial setup complexity
3.7 Growth potential analysis
3.8 Porter’s analysis
3.9 PESTEL analysis
CHAPTER 4 COMPETITIVE LANDSCAPE, 2023
4.1 Introduction
4.2 Company market share analysis
4.3 Competitive positioning matrix
4.4 Strategic outlook matrix
CHAPTER 5 MARKET ESTIMATES & FORECAST, BY COMPONENT, 2021-2032 (USD MILLION)
5.1 Key trends
5.2 Software
5.2.1 Soft PLC software
5.2.2 Standalone soft PLC
5.2.3 Embedded soft PLC
5.3 Virtual PLC software
5.3.1 Cloud-based virtual PLC
5.3.2 On-premises virtual PLC
5.4 Services
5.4.1 Consulting and integration services
5.4.2 Support and maintenance services
5.4.3 Training and education services
CHAPTER 6 MARKET ESTIMATES & FORECAST, BY PRODUCT TYPE, 2021-2032 (USD MILLION)
6.1 Key trends
6.2 Virtual PLC
6.3 Soft PLC
CHAPTER 7 MARKET ESTIMATES & FORECAST, BY CONTROL LEVEL TYPE, 2021-2032 (USD MILLION)
7.1 Key trends
7.2 Field level
7.3 Process level
7.4 Supervisory level
7.5 Enterprise level
CHAPTER 8 MARKET ESTIMATES & FORECAST, BY DEPLOYMENT MODE, 2021-2032 (USD MILLION)
8.1 Key trends
8.2 On-premises
8.3 Cloud-based
CHAPTER 9 MARKET ESTIMATES & FORECAST, BY OPERATING SYSTEM, 2021-2032 (USD MILLION)
9.1 Key trends
9.2 Windows-based
9.3 Linux-based
9.4 Others
CHAPTER 10 MARKET ESTIMATES & FORECAST, BY COMMUNICATION PROTOCOL, 2021-2032 (USD MILLION)
10.1 Key trends
10.2 Ethernet/IP
10.3 Profinet
10.4 Modbus TCP
10.5 Canopen
10.6 Others
CHAPTER 11 MARKET ESTIMATES & FORECAST, BY APPLICATION, 2021-2032 (USD MILLION)
11.1 Key trends
11.2 Discrete manufacturing
11.2.1 Assembly line automation
11.2.2 Packaging automation
11.2.3 Material handling systems
11.3 Process manufacturing
11.3.1 Chemical process control
11.3.2 Food and beverage processing
11.3.3 Pharmaceuticals
11.4 Others
CHAPTER 12 MARKET ESTIMATES & FORECAST, BY REGION, 2021-2032 (USD MILLION)
12.1 Key trends
12.2 North America
12.2.1 U.S.
12.2.2 Canada
12.3 Europe
12.3.1 UK
12.3.2 Germany
12.3.3 France
12.3.4 Italy
12.3.5 Spain
12.3.6 Russia
12.4 Asia Pacific
12.4.1 China
12.4.2 India
12.4.3 Japan
12.4.4 South Korea
12.4.5 Australia
12.5 Latin America
12.5.1 Brazil
12.5.2 Mexico
12.6 MEA
12.6.1 South Africa
12.6.2 Saudi Arabia
12.6.3 UAE
CHAPTER 13 COMPANY PROFILES
13.1 ABB Ltd.
13.2 Advantech Co., Ltd.
13.3 Beckhoff Automation
13.4 Bosch Rexroth
13.5 Delta Electronics, Inc.
13.6 Emerson Electric Co.
13.7 Hitachi Industrial Equipment Systems
13.8 Honeywell International Inc.
13.9 Koyo Electronics Industries Co., Ltd.
13.10 Lenze
13.11 Mitsubishi Electric
13.12 Omron Corporation
13.13 Phoenix Contact
13.14 Pilz GmbH & Co. KG
13.15 Red Lion Controls
13.16 Rockwell Automation
13.17 Schleicher Electronic GmbH & Co. KG
13.18 Schneider Electric
13.19 Siemens AG
13.20 WAGO Corporation
13.21 Yokogawa Electric Corporation
CHAPTER 1 METHODOLOGY & SCOPE
1.1 Market scope & definitions
1.2 Base estimates & calculations
1.3 Forecast calculations
1.4 Data sources
1.4.1 Primary
1.4.2 Secondary
1.4.2.1 Paid sources
1.4.2.2 Public sources
CHAPTER 2 EXECUTIVE SUMMARY
2.1 Industry synopsis, 2021-2032
Chapter Industry Insights
3.1 Industry ecosystem analysis
3.1.1 Factor affecting the value chain
3.1.2 Profit margin analysis
3.1.3 Disruptions
3.1.4 Future outlook
3.1.5 Manufacturers
3.1.6 Distributors
3.2 Supplier landscape
3.3 Profit margin analysis
3.4 Key news & initiatives
3.5 Regulatory landscape
3.6 Impact forces
3.6.1 Growth drivers
3.6.1.1 Rising adoption of industry 4.0 and smart manufacturing
3.6.1.2 Growing demand for remote monitoring and control
3.6.1.3 Integration with emerging technologies like AI and Edge computing
3.6.1.4 Increased focus on flexibility and scalability
3.6.2 Industry pitfalls & challenges
3.6.2.1 Cybersecurity risks and vulnerabilities
3.6.2.2 High initial setup complexity
3.7 Growth potential analysis
3.8 Porter’s analysis
3.9 PESTEL analysis
CHAPTER 4 COMPETITIVE LANDSCAPE, 2023
4.1 Introduction
4.2 Company market share analysis
4.3 Competitive positioning matrix
4.4 Strategic outlook matrix
CHAPTER 5 MARKET ESTIMATES & FORECAST, BY COMPONENT, 2021-2032 (USD MILLION)
5.1 Key trends
5.2 Software
5.2.1 Soft PLC software
5.2.2 Standalone soft PLC
5.2.3 Embedded soft PLC
5.3 Virtual PLC software
5.3.1 Cloud-based virtual PLC
5.3.2 On-premises virtual PLC
5.4 Services
5.4.1 Consulting and integration services
5.4.2 Support and maintenance services
5.4.3 Training and education services
CHAPTER 6 MARKET ESTIMATES & FORECAST, BY PRODUCT TYPE, 2021-2032 (USD MILLION)
6.1 Key trends
6.2 Virtual PLC
6.3 Soft PLC
CHAPTER 7 MARKET ESTIMATES & FORECAST, BY CONTROL LEVEL TYPE, 2021-2032 (USD MILLION)
7.1 Key trends
7.2 Field level
7.3 Process level
7.4 Supervisory level
7.5 Enterprise level
CHAPTER 8 MARKET ESTIMATES & FORECAST, BY DEPLOYMENT MODE, 2021-2032 (USD MILLION)
8.1 Key trends
8.2 On-premises
8.3 Cloud-based
CHAPTER 9 MARKET ESTIMATES & FORECAST, BY OPERATING SYSTEM, 2021-2032 (USD MILLION)
9.1 Key trends
9.2 Windows-based
9.3 Linux-based
9.4 Others
CHAPTER 10 MARKET ESTIMATES & FORECAST, BY COMMUNICATION PROTOCOL, 2021-2032 (USD MILLION)
10.1 Key trends
10.2 Ethernet/IP
10.3 Profinet
10.4 Modbus TCP
10.5 Canopen
10.6 Others
CHAPTER 11 MARKET ESTIMATES & FORECAST, BY APPLICATION, 2021-2032 (USD MILLION)
11.1 Key trends
11.2 Discrete manufacturing
11.2.1 Assembly line automation
11.2.2 Packaging automation
11.2.3 Material handling systems
11.3 Process manufacturing
11.3.1 Chemical process control
11.3.2 Food and beverage processing
11.3.3 Pharmaceuticals
11.4 Others
CHAPTER 12 MARKET ESTIMATES & FORECAST, BY REGION, 2021-2032 (USD MILLION)
12.1 Key trends
12.2 North America
12.2.1 U.S.
12.2.2 Canada
12.3 Europe
12.3.1 UK
12.3.2 Germany
12.3.3 France
12.3.4 Italy
12.3.5 Spain
12.3.6 Russia
12.4 Asia Pacific
12.4.1 China
12.4.2 India
12.4.3 Japan
12.4.4 South Korea
12.4.5 Australia
12.5 Latin America
12.5.1 Brazil
12.5.2 Mexico
12.6 MEA
12.6.1 South Africa
12.6.2 Saudi Arabia
12.6.3 UAE
CHAPTER 13 COMPANY PROFILES
13.1 ABB Ltd.
13.2 Advantech Co., Ltd.
13.3 Beckhoff Automation
13.4 Bosch Rexroth
13.5 Delta Electronics, Inc.
13.6 Emerson Electric Co.
13.7 Hitachi Industrial Equipment Systems
13.8 Honeywell International Inc.
13.9 Koyo Electronics Industries Co., Ltd.
13.10 Lenze
13.11 Mitsubishi Electric
13.12 Omron Corporation
13.13 Phoenix Contact
13.14 Pilz GmbH & Co. KG
13.15 Red Lion Controls
13.16 Rockwell Automation
13.17 Schleicher Electronic GmbH & Co. KG
13.18 Schneider Electric
13.19 Siemens AG
13.20 WAGO Corporation
13.21 Yokogawa Electric Corporation
