North America Process Automation Market Outlook
According to the report by Expert Market Research (EMR), the North America process automation market attained a value of approximately USD 36.01 billion in 2025. Aided by the increasing adoption of advanced industrial technologies and the growing emphasis on operational efficiency across key end-use industries, the market is projected to further grow at a CAGR of 5.30% between 2026 and 2035, reaching a value of around USD 60.35 billion by 2035.
Process automation refers to the use of control systems, software, and technologies to manage and operate industrial processes with minimal human intervention. These systems include distributed control systems (DCS), programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA), and advanced process control solutions. Process automation enhances productivity, improves product quality, ensures safety, and reduces operational costs, making it a crucial component across industries such as oil and gas, chemicals, pharmaceuticals, food and beverages, power generation, and manufacturing.
In North America, the rapid pace of industrial digital transformation, coupled with the increasing integration of artificial intelligence (AI), Internet of Things (IoT), and data analytics into automation systems, has significantly strengthened market growth. The region’s strong manufacturing base and continuous investments in smart factories and Industry 4.0 initiatives are also contributing to the expanding adoption of process automation solutions.
North America Process Automation Market Trends
One of the prominent trends shaping the North America process automation market is the growing shift towards smart manufacturing. Industries are increasingly implementing connected devices, real-time monitoring systems, and cloud-based automation platforms to improve visibility and operational control. The integration of AI and machine learning in process automation enables predictive maintenance, real-time optimisation, and enhanced decision-making, thereby improving overall plant performance.
Another key trend is the rising adoption of digital twins in industrial processes. Digital twin technology allows manufacturers to create virtual replicas of physical assets and processes, facilitating simulation, performance analysis, and process optimisation. This technology is gaining traction across sectors such as energy, chemicals, and manufacturing, as it helps reduce downtime and improve efficiency.
The increasing demand for sustainable and energy-efficient processes is also influencing automation trends. Automation systems are being designed to minimise waste, optimise energy consumption, and ensure compliance with environmental regulations. This aligns with the broader regional focus on sustainability and carbon footprint reduction.
Drivers of Growth
The primary driver of growth in the North America process automation market is the growing need for operational efficiency and cost reduction. Industries are under constant pressure to improve productivity while minimising expenses. Process automation helps achieve these goals by reducing manual intervention, minimising errors, and enhancing production speed and consistency.
The expanding adoption of Industry 4.0 technologies is another significant growth driver. The convergence of automation, data analytics, and connectivity is transforming traditional manufacturing operations into intelligent production systems. This digital transformation is encouraging organisations to invest heavily in automation solutions to remain competitive.
Furthermore, the increasing complexity of industrial processes is driving the demand for advanced automation systems. In sectors such as chemicals, pharmaceuticals, and energy, maintaining precise control over processes is critical for product quality and safety. Automation solutions provide accurate monitoring and control, ensuring regulatory compliance and improved operational outcomes.
The growing labour shortage in skilled industrial workers across North America is also boosting the demand for automation. With fewer workers available for manual operations, industries are turning to automation to maintain productivity and meet production targets.
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Industry Analysis
The North America process automation market is characterised by a high level of technological sophistication and strong competition among leading players. The United States dominates the regional market, owing to its extensive industrial infrastructure, high technology adoption rate, and substantial investments in smart manufacturing initiatives. Canada also contributes significantly, driven by automation adoption in energy, mining, and manufacturing sectors.
The oil and gas industry represents one of the largest end-users of process automation in the region. Automation systems are widely deployed for upstream, midstream, and downstream operations to improve safety, optimise production, and enhance asset management. The chemical and pharmaceutical industries also account for a substantial market share, as they require precise process control and strict regulatory compliance.
The food and beverage sector is increasingly adopting automation to ensure consistent product quality, improve hygiene standards, and enhance production efficiency. Similarly, the power generation industry relies heavily on automation systems to manage complex operations and ensure reliable energy supply.
North America Process Automation Industry 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
- United States of America
- Canada
Challenges and Opportunities
Despite the strong growth prospects, the North America process automation market faces certain challenges. One of the major hurdles is the high initial investment required for implementing advanced automation systems. Small and medium-sized enterprises (SMEs) may find it difficult to adopt these technologies due to budget constraints.
Another challenge is the complexity associated with integrating new automation systems with existing legacy infrastructure. Many industrial facilities operate on outdated systems, making the transition to modern automation solutions time-consuming and costly.
Cybersecurity risks also pose a significant challenge. As automation systems become more interconnected, they become vulnerable to cyberattacks that can disrupt operations and compromise sensitive data. Ensuring robust cybersecurity measures adds to the overall cost and complexity of automation projects.
North America Process Automation Market Forecast
The North America process automation market is poised for steady growth over the forecast period, driven by ongoing industrial digital transformation and increasing investments in smart manufacturing technologies. From a value of approximately USD 36.01 billion in 2025, the market is expected to grow at a CAGR of 5.30% between 2026 and 2035, reaching around USD 60.35 billion by 2035.
The continued adoption of AI-driven automation, IoT-enabled systems, and advanced analytics is anticipated to further enhance process efficiency and drive market demand. Industries such as oil and gas, chemicals, pharmaceuticals, and manufacturing will remain key contributors to market growth, while emerging applications in renewable energy and advanced manufacturing will create additional opportunities.
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