Discrete Automation Market Strategic Analysis and Key Developments

Global Discrete Automation Market size was valued at USD 7.28 Bn in 2024 and the total Global Discrete Automation Market revenue is expected to grow at 5.4% through 2025 to 2032, reaching nearly USD 11.09 Bn.

Global Discrete Automation Market Overview

The Global Discrete Automation Market was valued at USD 7.28 billion in 2024 and is projected to reach nearly USD 11.09 billion by 2032, growing at a CAGR of 5.4% during 2025–2032. This steady expansion is fueled by rising adoption of smart manufacturing technologies, the need for higher operational efficiency, and increasing emphasis on energy optimization across industrial sectors.

Discrete automation focuses on automating individual, task-specific manufacturing processes involving distinct and countable products such as automotive components, electronics, machinery parts, and packaged goods. The market leverages technologies including programmable logic controllers (PLCs), robotics, sensors, motion control systems, and industrial software, enabling manufacturers to achieve high-speed, precise, and repeatable production while minimizing operational costs.

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Market Growth Drivers

Efficiency, Productivity, and Cost Optimization

One of the strongest growth drivers of the discrete automation market is the growing industrial focus on efficiency enhancement and cost reduction. Automated systems reduce dependency on manual labor, minimize errors, improve production throughput, and ensure consistent product quality. These benefits are especially critical in industries facing high-volume production demands and tight margins.

Urbanization and Infrastructure Expansion

Rapid urbanization and population growth are increasing pressure on infrastructure development worldwide. Discrete automation is increasingly deployed across industries such as pharmaceuticals, chemicals, mining, pulp & paper, and utilities, enabling scalable production while managing rising demand efficiently.

Renewable Energy and Energy-Efficient Manufacturing

Government initiatives promoting energy-efficient technologies and renewable energy adoption are further supporting market growth. Investments in sectors such as water and wastewater management, oil & gas, power generation, and electricity transmission are driving demand for automated control systems that enhance reliability and reduce energy consumption.

Market Segmentation Analysis

By Type

The global discrete automation market is segmented into:

Programmable Logic Controllers (PLCs)
Manufacturing Execution Systems (MES)
Distributed Control Systems (DCS)
Product Lifecycle Management (PLM)
Among these, PLCs are expected to hold the largest market share by 2032. PLCs improve operational speed, enhance system reliability, and significantly reduce human error in industrial processes. Growing adoption in food processing, packaging, and automotive manufacturing is boosting PLC demand.

MES platforms play a vital role by acting as a bridge between enterprise resource planning (ERP) systems and shop-floor operations. They provide real-time visibility into production status, manpower utilization, process parameters, and resource consumption. Meanwhile, PLM solutions support end-to-end product development by managing design, manufacturing, and lifecycle data efficiently.

By Application

Based on application, the market is segmented into:

Automotive
Packaging
Textile
Aerospace & Defense
Others
The automotive sector accounted for the largest share in 2024, driven by rising production of lightweight and electric vehicles, especially in emerging economies such as India and China. Discrete automation enables precision manufacturing, improved safety, and faster assembly lines, making it indispensable in modern automotive production environments.

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Regional Insights

North America

North America dominated the global discrete automation market in 2024 and is expected to maintain its leadership throughout the forecast period. The region benefits from advanced manufacturing infrastructure, widespread Industry 4.0 adoption, and supportive government policies. In the United States, newly introduced industrial strategies are encouraging higher investments in automation technologies, further strengthening regional growth.

Asia Pacific

Asia Pacific represents the fastest-growing regional market, supported by rapid industrialization and expanding manufacturing bases in countries such as China, India, South Korea, and Indonesia. The region’s strong textile industry, availability of raw materials, and cost-effective skilled labor provide a favorable environment for automation adoption. Government initiatives aimed at boosting manufacturing output and exports are further accelerating market expansion.

Competitive Landscape

The global discrete automation market is highly competitive, with key players focusing on AI-driven automation, IIoT-enabled platforms, edge computing, and scalable control systems.

Emerson Electric Co. remains a prominent player, competing with industry leaders such as Siemens, Rockwell Automation, and ABB. Emerson differentiates itself through its DeltaV and PACSystems portfolios, modular control architectures, and strong presence in hybrid and batch-processing industries like pharmaceuticals, energy, and mining.

While Siemens leads in broad industrial automation and Rockwell Automation dominates North American manufacturing, Emerson continues to strengthen its market position through strategic acquisitions, AI integration, and partnerships with cloud service providers such as AWS and Microsoft.

Key Market Trends

AI and Edge Computing Integration: Manufacturers are embedding AI capabilities directly into PLCs to enable autonomous decision-making and predictive maintenance.
Modular and Scalable Automation Systems: Open platforms and API-based designs are allowing faster deployment and greater customization.
Sustainability-Focused Automation: Increasing regulatory pressure for green manufacturing is driving automation adoption in EV production and renewable energy sectors.
Recent Developments

Honeywell (US) – May 2024: Launched an AI-powered automation suite integrating edge computing and IIoT for predictive maintenance.
Siemens (Germany) – September 2024: Introduced an advanced PLC platform with native AI for real-time quality control.
Mitsubishi Electric (Japan) – July 2025: Debuted a high-speed automation system with quantum-safe encryption.
Schneider Electric (France) – March 2025: Released a software-centric automation platform enabling seamless IT/OT integration.
Stäubli International AG (Switzerland) – October 2024: Launched a high-payload collaborative robot targeting automotive and aerospace applications.
Conclusion

The Global Discrete Automation Market continues to play a pivotal role in transforming modern manufacturing. With increasing emphasis on smart factories, digitalization, sustainability, and data-driven decision-making, discrete automation technologies are becoming indispensable across industries. As AI, edge computing, and green manufacturing gain momentum, the market is expected to witness sustained growth, offering attractive opportunities for technology providers, manufacturers, and investors worldwide.