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市場調查報告書
商品編碼
1822346
安全可程式控制器市場預測(至 2032 年):按類型、技術、應用、最終用戶和地區進行的全球分析Safety Programmable Controller Market Forecasts to 2032 - Global Analysis By Type (Modular Safety PLCs and Compact Safety PLCs), Technology, Application, End User and By Geography |
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根據 Stratistics MRC 的預測,全球安全可程式控制器市場規模預計在 2025 年達到 5.6833 億美元,到 2032 年將達到 9.9955 億美元,預測期內的複合年成長率為 8.4%。
安全可程式控制器 (SPC) 是一種先進的自動化系統,專門用於監控工業環境中的本質安全操作。其主要作用是將機器保持在安全運作範圍內,降低事故、設備故障和人員危害的風險。與傳統 PLC 不同,SPC 整合了故障偵測、冗餘和緊急關斷功能,以符合 IEC 61508 和 ISO 13849 等嚴格的安全法規。 SPC 通常部署在工廠、加工廠和機器人系統中,它結合了可程式安全邏輯、感測器和致動器的無縫整合以及持續監控。在現代工業應用中,SPC 對於確保營運效率和職場安全至關重要。
根據美國職業安全與健康管理局和美國勞工部的數據,職場的傷害、疾病和死亡每年給美國企業造成超過 1,700 億美元的直接和間接成本,包括醫療費用、生產力損失、保險費和法律責任。
提高職場安全意識
職場安全意識的不斷增強推動了對安全可程式控制器的需求。各組織越來越意識到保護員工和確保工業環境中安全操作的必要性。可程式控制器 (SPC) 提供故障偵測、機器監控和緊急停止等關鍵功能,顯著降低了事故風險和操作隱患。安全培訓計劃、意識提升宣傳活動和公司政策等措施進一步強調了安全管理的重要性。公眾關注和法律規範正在鼓勵各行各業整合先進的安全解決方案,從而推動 SPC 的採用率不斷提升。
初期投資成本高
安全可程式控制器的高昂初始投資成本對市場成長構成了挑戰。實施安全可程式控制器 (SPC) 需要大量的設備、軟體、整合以及在現有工業設施中的安裝成本。對於許多中小型企業而言,這些成本是一個主要限制因素,常常導致實施進度延遲或削減。此外,培訓員工以有效管理和維護控制器的成本也很高。雖然 SPC 能夠帶來諸如提高安全性和工作效率等長期效益,但高昂的初始資本需求使企業不願投資。因此,高昂的資本要求仍然是一個主要限制因素,減緩了全球工業領域對安全可程式控制器的整體採用。
工業 4.0 技術的應用日益廣泛
工業 4.0 的興起為安全可程式控制器市場提供了巨大的成長潛力。隨著各行各業擁抱智慧製造、物聯網連接和先進機器人技術,確保營運安全變得至關重要。可程式控制器 (SPC) 與感測器、致動器和互聯機械整合,可實現即時監控、緊急停機和故障檢測。這種相容性使企業能夠在保持嚴格安全標準的同時提高生產力和效率。製造業、汽車業、能源業和化工業等領域正在進行的數位轉型正在推動對先進安全控制器的需求。因此,工業 4.0 技術的採用正在為全球可程式控制器製造商和解決方案供應商創造光明的成長前景,為市場的長期擴張奠定基礎。
技術快速淘汰
工業自動化和控制系統技術創新的快速發展對安全可程式控制器市場構成威脅。隨著硬體、軟體和通訊協定的不斷發展,現有的可程式控制器 (SPC) 很快就會過時。企業可能會推遲投資,期待功能更強大、更先進的控制器的出現。為了與最新的機器、物聯網系統和更新的軟體保持相容,通常需要頻繁升級,從而推高營運成本。較舊的 SPC 型號面臨著與新技術整合的挑戰,可能會影響性能和可靠性。由於各行各業必須不斷平衡安全性、成本和技術可行性,這種快速的技術更新換代帶來了持續的挑戰,可能會阻礙市場擴張並減緩 SPC 的普及。
新冠疫情爆發擾亂了全球製造業、供應鏈和工業活動,對安全可程式控制器市場造成了重大衝擊。停工、勞動力短缺和營運限制導致可程式控制器(SPC)的生產、部署和服務延遲,工業自動化計劃停滯不前。景氣衰退時期企業投資削減進一步抑制了先進安全解決方案的採用。同時,疫情凸顯了自動化和遠端安全監控在減少危險工作場所人員暴露方面的重要性,從而提高了人們對工業安全的認知。隨著營運逐漸恢復正常,對可程式控制器(SPC)的需求也隨之回升,推動了全球對自動化、互聯互通和數位化管理的工業系統中可靠安全控制器的需求。
模組化安全 PLC 市場預計將在預測期內佔據最大佔有率
模組化安全PLC細分市場預計將在預測期內佔據最大的市場佔有率,這得益於其適應性、擴充性以及對複雜安全關鍵操作的適用性。其模組化架構允許整合各種I/O模組、通訊選項以及根據特定工業需求量身定做的安全功能。這些控制器廣泛應用於汽車、化學、製造和能源等關鍵流程的可靠監控和控制至關重要的領域。其模組化設計也方便維護、系統升級和擴展,使其成為大型、快速擴張的工業設施的理想選擇。其固有的靈活性和滿足各種安全要求的能力鞏固了其市場主導地位,並將繼續推動其在全球範圍內的廣泛應用。
預計半導體和電子產業在預測期內將實現最高的複合年成長率。
預計在預測期內,半導體和電子產業將實現最高成長率,這得益於電子製造業自動化程度和複雜性的不斷提高。現代半導體和電子製造業涉及高速機械、精密製程和敏感元件,因此先進的安全系統對於預防事故和保護設備至關重要。 SPC 提供即時監控、故障偵測和緊急關斷等關鍵功能,確保符合嚴格的安全標準。電子產品、微型元件和自動化生產技術的需求激增,推動了對可靠安全控制器的需求。因此,半導體和電子產業是全球 SPC 市場的主要成長要素。
在預測期內,歐洲預計將佔據最大的市場佔有率,這得益於成熟的工業部門、強大的製造能力和嚴格的安全標準。德國、法國和英國等主要國家正在積極實施符合 IEC 61508 和 ISO 13849 等法規的工業自動化和先進安全解決方案。對員工安全、技術進步以及工業 4.0 在汽車、化學和能源等行業的整合的重視,正在加速 SPC 的採用。此外,主要市場參與者的存在、強大的研發基礎設施以及對智慧製造的投資,正在鞏固歐洲的主導地位,並使其成為全球領先的安全可編程控制器區域市場。
受快速工業化、自動化程度不斷提高以及對智慧製造投資的推動,預計亞太地區在預測期內的複合年成長率最高。中國、日本、韓國和印度等主要國家汽車、電子和製造業的快速擴張,推動了對可靠安全系統的需求。人們對職場安全的日益關注、政府的支持性政策以及現代化舉措,進一步加速了統計過程控制 (SPC) 的普及。由於不斷發展的工業基礎設施、對安全標準的遵守以及對營運效率的關注,亞太地區成為成長最快的市場。
According to Stratistics MRC, the Global Safety Programmable Controller Market is accounted for $568.33 million in 2025 and is expected to reach $999.55 million by 2032 growing at a CAGR of 8.4% during the forecast period. Safety Programmable Controllers (SPCs) are advanced automation systems specifically developed to oversee and control essential safety operations in industrial settings. Their primary role is to maintain machinery within safe operating limits, reducing the risk of accidents, equipment failure, and hazards to workers. Differing from conventional PLCs, SPCs feature fault detection, redundancy, and emergency shutdown capabilities to comply with rigorous safety regulations such as IEC 61508 and ISO 13849. Commonly implemented in factories, process plants, and robotic systems, they combine programmable safety logic, seamless sensor and actuator integration, and continuous monitoring. SPCs are indispensable for ensuring both operational efficiency and workplace safety in contemporary industrial applications.
According to OSHA and the U.S. Department of Labor, workplace injuries, illnesses, and fatalities cost U.S. businesses over $170 billion annually in direct and indirect expenses-including medical costs, lost productivity, insurance premiums, and legal liabilities.
Growing awareness about workplace safety
Heightened awareness regarding workplace safety is driving the demand for Safety Programmable Controllers. Organizations are increasingly conscious of the need to protect employees and ensure secure operations within industrial environments. SPCs offer critical capabilities, including fault detection, machinery monitoring, and emergency stop functions, which significantly reduce accident risks and operational hazards. Initiatives such as safety training programs, awareness campaigns, and internal corporate policies are further emphasizing the importance of safety management. Public attention and regulatory oversight have motivated industries to integrate advanced safety solutions, leading to increased deployment of SPCs.
High initial investment cost
The substantial upfront cost of Safety Programmable Controllers poses a challenge for market growth. Deployment of SPCs requires significant spending on equipment, software, integration, and installation within existing industrial setups. For many small and medium enterprises, these expenses are a major constraint, often causing delays or reduced implementation. Additional costs include training staff to effectively manage and maintain the controllers. Although SPCs provide long-term advantages like enhanced safety and operational efficiency, the high initial financial commitment can deter organizations from investing. Consequently, the considerable capital requirement remains a key restraint, slowing the overall adoption of Safety Programmable Controllers in industrial sectors worldwide.
Growing adoption of industry 4.0 technologies
The rise of Industry 4.0 offers substantial growth potential for the Safety Programmable Controller market. As industries embrace smart manufacturing, IoT connectivity, and advanced robotics, ensuring operational safety becomes paramount. SPCs enable real-time monitoring, emergency shutdowns, and fault detection by integrating with sensors, actuators, and interconnected machinery. This compatibility allows companies to uphold strict safety standards while enhancing productivity and efficiency. The ongoing digital transformation in sectors such as manufacturing, automotive, energy, and chemicals is driving demand for advanced safety controllers. Consequently, the adoption of Industry 4.0 technologies is creating promising growth avenues for SPC manufacturers and solution providers globally, positioning the market for long-term expansion.
Rapid technological obsolescence
The fast pace of innovation in industrial automation and control systems threatens the Safety Programmable Controller market. As hardware, software, and communication protocols evolve, existing SPCs may become outdated quickly. Companies may delay investments, anticipating the arrival of more advanced controllers with enhanced capabilities. Maintaining compatibility with modern machinery, IoT systems, and updated software often necessitates frequent upgrades, raising operational costs. Older SPC models may face integration issues with new technologies, affecting performance and reliability. This rapid technological obsolescence creates a persistent challenge, potentially hindering market expansion and slowing widespread adoption of SPCs, as industries must continuously balance safety, cost, and technological relevance.
The COVID-19 outbreak significantly affected the Safety Programmable Controller market by disrupting manufacturing, supply chains, and industrial activities worldwide. Lockdowns, labor shortages, and operational restrictions caused delays in the production, deployment, and servicing of SPCs, slowing industrial automation projects. Companies' reduced investments during the economic downturn further constrained adoption of advanced safety solutions. At the same time, the pandemic highlighted the value of automation and remote safety monitoring to reduce human exposure in hazardous workplaces, increasing awareness of industrial safety. As operations gradually normalized, SPC demand rebounded, driven by the growing need for dependable safety controllers in automated, connected, and digitally managed industrial systems globally.
The modular safety PLCs segment is expected to be the largest during the forecast period
The modular safety PLCs segment is expected to account for the largest market share during the forecast period, owing to their adaptability, scalability, and suitability for complex safety-critical operations. Their modular architecture enables the integration of different I/O modules, communication options, and safety features tailored to specific industrial needs. These controllers are extensively used across automotive, chemical, manufacturing, and energy sectors, where dependable monitoring and control of critical processes are essential. The modular approach also facilitates easier maintenance, system upgrades, and expansion, making them ideal for large and evolving industrial facilities. Their inherent flexibility and capability to meet diverse safety requirements reinforce their leading market position and continued widespread adoption globally.
The semiconductors & electronics segment is expected to have the highest CAGR during the forecast period
Over the forecast period, the semiconductors & electronics segment is predicted to witness the highest growth rate, driven by the rising automation and complexity of electronic manufacturing. Modern semiconductor and electronics production involves high-speed machinery, precision processes, and delicate components, making advanced safety systems essential to prevent accidents and safeguard equipment. SPCs offer critical features such as real-time monitoring, fault detection, and emergency shutdowns, ensuring compliance with stringent safety standards. With the booming demand for electronic devices, miniaturized components, and automated production technologies, the requirement for reliable safety controllers is intensifying. This makes the Semiconductors & Electronics segment a key growth driver in the global SPC market.
During the forecast period, the Europe region is expected to hold the largest market share, supported by its mature industrial sector, robust manufacturing capabilities, and strict safety standards. Leading countries including Germany, France, and the UK have actively implemented industrial automation and advanced safety solutions in line with regulations such as IEC 61508 and ISO 13849. The emphasis on employee safety, technological advancement, and Industry 4.0 integration across sectors like automotive, chemical, and energy has accelerated SPC adoption. Additionally, the presence of major market players, substantial R&D infrastructure, and investments in intelligent manufacturing reinforce Europe's leading position, establishing it as a key regional market for Safety Programmable Controllers worldwide.
Over the forecast period, the Asia Pacific region is anticipated to exhibit the highest CAGR, driven by fast-paced industrialization, growing automation, and investments in smart manufacturing. Major economies including China, Japan, South Korea, and India are rapidly expanding their automotive, electronics, and manufacturing industries, fueling the need for reliable safety systems. Increasing focus on workplace safety, supportive government policies, and modernization initiatives further accelerate SPC adoption. The region's combination of evolving industrial infrastructure, compliance with safety standards and emphasis on operational efficiency positions Asia-Pacific as the fastest-growing market.
Key players in the market
Some of the key players in Safety Programmable Controller Market include ABB, Keyence Corporation, Mitsubishi Electric Corporation, Omron Corporation, IFM Electronic GmbH, HIMA Group, IDEC Corporation, Schneider Electric SE, Rockwell Automation, Inc., Pilz GmbH & Co.KG, Sick AG, Siemens AG, Honeywell International Inc., Treotham and B&R Industrial Automation.
In September 2025, ABB and Codelco have announced their latest collaboration to optimise the Chilean state-owned copper mining company's maintenance program. With Chile currently the world's largest copper producer, this latest long-term service agreement (LTSA) encompasses maintenance, remote diagnostics and skills training to enhance the performance of its gearless mill drive (GMD) systems.
In September 2025, Mitsubishi Electric Corporation announced that it has entered into an agreement to acquire all shares of Nozomi Networks Inc., a U.S.-based developer and distributor of operational technology (OT) security solutions. Nozomi Networks serves a diverse range of customers, primarily in social infrastructure sectors such as power and railways, as well as in the manufacturing industry. This acquisition pertains to shares not already owned by Mitsubishi Electric.
In July 2025, OMRON Corporation announced that it has entered into a strategic partnership agreement with Japan Activation Capital, Inc. to accelerate sustainable growth and enhance long-term corporate value at OMRON. Under the Partnership Agreement, OMRON will collaborate closely with JAC to achieve this shared vision by leveraging JAC's position as a strategic partner. JAC holds shares in OMRON through its managed funds.
Note: Tables for North America, Europe, APAC, South America, and Middle East & Africa Regions are also represented in the same manner as above.