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United States Process Automation Market Size, Share and Report | 2026-2035
United States Process Automation Market
According to the report by Expert Market Research (EMR), the United States process automation market reached a value of approximately USD 32.82 billion in 2025. The market has been witnessing steady growth, supported by the increasing adoption of automation technologies across manufacturing, energy, chemicals, pharmaceuticals, food and beverages, and other industrial sectors. Aided by the growing focus on operational efficiency, cost optimisation, and improved process reliability, the market is projected to grow at a CAGR of 5.20% between 2026 and 2035, attaining a value of around USD 54.49 billion by 2035.
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Process automation refers to the use of control systems, software, and instrumentation to automate industrial and business processes with minimal human intervention. These systems play a crucial role in enhancing productivity, ensuring consistent quality, improving safety, and reducing downtime. In the United States, process automation has become an integral component of modern industrial operations, driven by technological advancements and the need to remain competitive in a global market.
United States Process Automation Market Trends
One of the key trends shaping the United States process automation market is the increasing integration of digital technologies such as artificial intelligence (AI), machine learning, and the industrial internet of things (IIoT). These technologies enable real-time data collection, predictive maintenance, and advanced analytics, thereby enhancing decision-making and process efficiency. The growing adoption of smart factories and Industry 4.0 initiatives is further accelerating the deployment of advanced automation solutions.
Another significant trend is the rising demand for cloud-based and software-centric automation platforms. Companies are increasingly shifting towards scalable and flexible automation systems that allow remote monitoring, system integration, and seamless upgrades. Additionally, the emphasis on energy efficiency and sustainability is encouraging industries to implement automated solutions that optimise resource utilisation and reduce emissions.
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Drivers of Growth
The primary driver of growth in the United States process automation market is the increasing need to improve operational efficiency while reducing labour costs. Automation helps organisations streamline complex processes, minimise human error, and enhance overall productivity, making it a critical investment for industries facing rising operational expenses.
The growing complexity of industrial processes and stringent regulatory requirements are also contributing to market expansion. Industries such as pharmaceuticals, chemicals, and food processing require precise process control and compliance with strict quality and safety standards, which can be effectively achieved through automation systems. Furthermore, the shortage of skilled labour in certain industrial sectors is prompting companies to adopt automated solutions to maintain production continuity.
United States Process Automation Market Segmentation
The market can be divided based on system type, communication protocol, application and region.
Market Breakup by System Type
Supervisory Control and Data Acquisition (SCADA)
Programmable Logic Controller (PLC)
Distributed Control System (DCS)
Machine Execution System (MES)
Valves and Actuators
Electric Motors
Human Machine Interface (HMI)
Process Safety Systems
Sensors and Transmitters
Others
Market Breakup by Communication Protocol
Wired Protocol
Wireless Protocol
Market Breakup by Application
Oil and Gas
Chemicals and Mining
Consumer Goods
Pharma and Biotech
Water and Wastewater
Automotive
Power
Others
Market Breakup by Region
New England
Mideast
Great Lakes
Plains
Southeast
Southwest
Rocky Mountain
Far West
Competitive Landscape
Some of the major players explored in the report by Expert Market Research are as follows:
ABB Ltd.
Siemens AG
Schneider Electric SE
General Electric Co.
Rockwell Automation Inc.
Emerson Electric Co.
Honeywell International Inc.
Mitsubishi Electric Corp.
Fuji Electric Co Ltd
Yokogawa Electric Corp.
Others
Challenges and Opportunities
Despite its positive outlook, the process automation market faces challenges such as high initial investment costs and integration complexities with legacy systems. Small and medium-sized enterprises, in particular, may hesitate to adopt automation due to budget constraints and concerns regarding return on investment.
However, these challenges are creating significant opportunities for technology providers. The development of modular, cost-effective, and user-friendly automation solutions is making automation more accessible to a wider range of businesses. Additionally, the increasing focus on cybersecurity and secure automation systems presents opportunities for vendors offering robust and compliant solutions tailored to the evolving industrial landscape.
United States Process Automation Market Forecast
Over the forecast period of 2026-2035, the United States process automation market is expected to witness sustained growth, supported by ongoing digital transformation and industrial modernisation. With a projected CAGR of 5.20%, the market is anticipated to reach a value of approximately USD 54.49 billion by 2035, reinforcing its vital role in enhancing productivity and competitiveness across US industries.
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