#smart automation solutions

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Smart Factory and Industrial Automation Market - Forecast(2024 - 2030)

 Overview

The smart factory and industrial automation market is expected to be valued at $187.8 billion in 2018 and is expected to grow at a CAGR of 7.2% between 2019 and 2025. This market growth is due to the impact of evolution and adoption of the Internet of Things (IoT), industrial robots, smart automation solutions, and increasing emphasis on regulatory compliances. Industrial and commercial developments in the growing economies are also responsible for the growth of this market.

Industrial automation is defined as the automation of industrial processes through computers, communication systems, and process operators. Industrial automation minimizes human intervention in the industry and ensures a superior performance as compared to humans. Moreover, whereas, smart factory connects people, processes, and machines to enable advanced manufacturing with the optimized process reduced errors, improved quality, and eliminate waste.

Both smart factory and industrial automation enhance the productivity and quality of products and simultaneously decrease the production cost. Smart factory and industrial automation meet the demand for mass production with providing nominal human intervention, better quality, and less labor expenses, significantly reduce overall operational cost.

Report Coverage

The report: “Smart Factory and Industrial Automation Market – Forecast (2019-2025)”, by IndustryARC covers an in-depth analysis of the following segments of the Smart Factory and Industrial Automation Market 

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Key Takeaways

· Key drivers of the market are; reduction of energy consumption and increasing factory efficiency. All the Industries are adopting smart factory concept to ensure that every component of the value chain is connected for providing informed manufacturing with no-time lags and zero defects.

· The automotive manufacturing sector has been one of the largest adopters of automated robots and is the largest the revenue-generating end-user in the market. Smart factory and industrial automation play an important role in connecting and automating the operations of these robots.

· Industrial Automation in China has increased the uptake of smart manufacturing. As per the Ministry of Industry and Information Technology, China initiated around 100 smart manufacturing pilot projects in 2018.

By Application - Segment Analysis

Material handling application generated 38% of the smart factory and industrial automation market revenue in 2018. Robotics and automation system is helping in business according to their growing demands and making it cost-efficient, and these advances in technology are a material handling system more affordable and effective. This high-speed automation technology can load and unload the truck at the pallet and cartoon level. Over the next decade, material handling is expected to immerse with the automated system highly.

Various advancements have been made in the automation of the multiple activities that were formerly carried out manually (particularly in the labor-intensive manufacturing industry), with most of these being almost fully automated, with the help of the latest technologies. This has led to improved efficiency, high-quality products, and attendant savings in labor and costs.

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By End-User - Segment Analysis

Automotive industry end-use accounted for the highest market share in the smart factory and industrial automation market in 2018. Smart factory solutions play a key role in the development and production of quality automobiles. The automobile manufacturing industry is the largest adopter of robots in 2018 (according to the international federation of robotics {IFR}). For enhance quality and increase factory productivity, while using these robots, smart factory and industrial automation solutions play a major role.

The fastest-growing end-use in the forecasted period is the energy and power sector. The sector consists of the gas industry, petroleum industry, coal industry, power industry, among others. The adoption rate of smart factory technology is expected to be the highest in the oil & gas industry due to the growing need for safety in oil and gas plants. The automation market has penetrated the energy sector in developed economies.

By Geography - Segment Analysis

APAC accounted for the largest share, of 34% in the smart factory and industrial automation market in 2018, due to technological innovation and adoption of automation technologies across several industries. Toyota, Honda, and Suzuki are working on developing smart factories. These smart and automated factories will be manufacturing robots, sensors, wireless technologies, and machine vision systems.

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Drivers – Smart Factory and Industrial Automation Market

·         GROWTH IN ADOPTION OF INDUSTRIAL ROBOTS:

The call for precision machining along with high production rates, has made use of robots an indispensable aspect of manufacturing units. Since the industrial operations are becoming complex amidst rapid technological advancements, the growth of the industrial robot is expected among such environment that is beyond the capacity of manual involvement. Smart factory and industrial automation play an essential role in connecting and automating the operations of these robots.

Almost all the processes in the production and processing plants have been automated in the past decade. This has also complemented the expansion of industrial robots integration into industrial operations.  

·         RISING LABOR COSTS TO BOOST THE SMART & AUTOMATED INDUSTRIAL ROBOTS DEMAND

The labor cost is significantly high in the total industrial operating cost, generally making 60%-65% of the total cost. In the majority of the cases, manual jobs typically consist of two categories of staff: direct and indirect. Direct staff is responsible for executing the procedure while the indirect staff is for the back-end support for direct staff.

The presence of both direct and indirect staff coupled along with department managers presents an essential cost in operating a warehouse.

The automation of industries has become a notable means to tackle the rising wages and workforce age. This has resulted in the industrial operators to rely upon the smart factories and automated robotics to provide a convenient and efficient way of reducing the operational costs while simultaneously maintaining the productivity at optimum levels.

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Challenges – Smart Factory and Industrial Automation Market

·         GROWTH OF CYBER ATTACKS

The history of the smart factory and industrial automation is always fascinating. Cybersecurity is one of the major issues of factory automation. Constant technological innovation has taken manufacturing processes from the Industrial Age to the information age as networking in process automation grows. These new information age factories have a great scope of cyber threats from various sources. These cyber-attacks can reduce the advantages of smart and automated factories and turn them into significant disadvantages.

For almost every minute, the global cybersecurity researchers discover threats to cybersecurity and try to solve them in real-time.

Market Landscape

Top 5 players of the smart factory and industrial automation market captured ~65% share of the market in 2018.

ABB Ltd., Mitsubishi Electric, Yokogawa, Endress+Hauser, Honeywell, Rockwell Automation, Omron, General Electric, Danfoss, FANUC, Schneider, Siemens, and Emerson Electric Company are some leading key players in the smart factory and industrial automation market.

Partnerships/Mergers/Acquisitions

Ø In July 2018, GE and Microsoft Corp. formed a partnership to bring together operational technology and information technology to eliminate hurdles in advancing digital transformation projects. In the partnership, GE Digital plans to standardize its Predix solutions on Microsoft Azure and will deeply integrate the Predix portfolio with Azure native cloud capabilities, including Azure IoT and Azure Data and Analytics.

Ø In June 2018, SAP and Endress+Hauser collaborated in the development of the Industrial Internet of Things (IIoT) applications for the process industry. The goal is to fully integrate the Endress+Hauser field instruments as digital twins into the SAP cloud platform.

Ø June 2018, PTC Inc. and Rockwell Automation Inc. formed a strategic partnership that accelerated growth for both companies and enabled them to be the partner of choice for customers around the world who want to transform their physical operations with digital technology.

R&D Investment/Fundings

Ø In July 2019, Fetch Robotics raised $46 million in a Series C round of funding led by Fort Ross Ventures. Fetch Robotics creates autonomous robots, powered by cloud-based software systems, which operate in locations such as warehouses, factories, and distribution centers. The robots can be used to transport goods and materials around warehouses, gather data automatically.

Smart Factory and Industrial Automation Market Research Scope:

The base year of the study is 2018, with forecast done up to 2025. The study presents a thorough analysis of the competitive landscape, taking into account the market shares of the leading companies. These provide the key market participants with the necessary business intelligence and help them understand the future of the Smart Factory and Industrial Automation Market. The assessment includes the forecast, an overview of the competitive structure, the market shares of the competitors, as well as the market trends, market demands, market drivers, market challenges, and product analysis. The market drivers and restraints have been assessed to fathom their impact over the forecast period. This report further identifies the key opportunities for growth while also detailing the key challenges and possible threats. The key areas of focus include the offering type, robot type, end-users, and application of Smart Factory and Industrial Automation Market.

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Smarter Surface Protection – PLC Automation in Autophoretic Coating Plants

In modern manufacturing, surface coating is not just cosmetic—it’s essential for durability, corrosion resistance, and performance. Autophoretic coating (also known as A-coating) has emerged as a water-based, eco-friendly alternative to electro-coating. When combined with PLC-based automation, it becomes a powerful, scalable solution for high-quality, uniform metal finishing.

Because let’s face it—metal without proper protection is like a knight without armour. In today’s industrial world, that armour comes in the form of surface coating. And when it comes to smart, sustainable, and scalable coating, autophoretic coating is the unsung hero.

But wait, here’s where it gets exciting. Pair this eco-warrior coating with PLC automation, and what you get is nothing short of magic. At Messung Industrial Automation, we believe that the perfect coat is not just about shine—it's about smarts, speed, and sustainability.Let’s dive into the world where chemistry meets code, and surface protection meets the future.

What is Autophoretic Coating?

Autophoretic coating, also known as A-coating, is a process where metal parts are dipped in a reactive water-based solution. The result? A self-depositing layer forms on the surface, without any electric current. Unlike traditional methods that zap the surface with electricity, A-coating lets chemistry take the wheel.

Why Are Industries Making the Switch?

Industries are coating their bets on it because it avoids the need for heavy electric setups and provides uniform coverage even in complex geometries.  Since it is water-based, it is also very environmentally friendly.

Where Is It Being Used?

From under-the-hood car parts to refrigerator frames, autophoretic coating is making waves in:

Automotive parts

Appliance components

Agricultural and construction machinery

General industrial structures

In an age where efficiency, sustainability, and performance go hand in hand, autophoretic coating emerges as a transformative solution. Its simplicity belies its power, ushering in a cleaner, smarter way to protect surfaces without compromising on quality or cost. As industries across the board continue to embrace greener practices, A-coating, powered by automation and intelligence, is painting the future—one seamless coat at a time.

 Role of PLC in the Coating Plant

In the realm of autophoretic coating, precision isn't a luxury—it's a necessity, and that precision begins with the silent genius of automation: the Programmable Logic Controller (PLC). Think of the PLC as the central nervous system of your coating plant—connecting, communicating, and commanding every mechanical muscle with machines. Here is how PLCs turn a basic coating line into a harmonious dance of efficiency and intelligence.

Precision Process Automation

A modern autophoretic coating plant runs smoothly like a well-coordinated team, and the PLC (Programmable Logic Controller) is in charge. It doesn’t just control the machines—it helps everything work perfectly together. From:

Tank temperature

Solution pressure & pH levels

Cycle timing for each dip and rise

...every step is monitored and controlled by PLC automation.

Material Handling Magic

Using intelligent material handling controllers, our PLC guides parts through multiple stages:

Degreasing

Surface conditioning

Coating dip

Rinsing & curing

Like a choreographer directing a ballet of metal.

Circulation & Filtration Mastery

Good coating = Consistent flow. Our process controllers and PLC control systems manage:

Fluid circulation

Filtration cycles

Solution replacement timing

Synchronisation with Process Controllers

Through seamless synchronisation with motion control systems, everything moves with precision. No drips, no downtime.

In an industry where milliseconds matter and uniformity is sacred, PLC automation elevates the autophoretic coating plant from functional to phenomenal. It enables not just control, but clarity—ensuring that every part, every dip, and every process flows with intelligent intent.

NX-ERA JET PLC System Architecture

Our flagship—NX-ERA JET PLC—is a robust, real-time, and rugged automation genius. It’s compact, reliable, and battle-tested in industrial heat.

Talk the Talk: MODBUS & TCP/IP

Built-in PLC communication protocols like:

MODBUS TCP/IP

MODBUS RTU

Make it plug-and-play with SCADA and automation systems. Yes, it speaks fluent-machine.

Ethernet-Based Controllers for High-Speed Sync

Using Ethernet-based controllers, data flows like molten metal. Zero lag, maximum productivity.

HMI with PLC Controllers

With user-friendly HMIs with PLC controllers, even a non-techie can operate complex coating sequences. Tap, drag, drop—and coat!

From seamless communication to intuitive control, the NX-ERA JET PLC is more than just a controller—it's the central nervous system of your autophoretic coating plant. With its advanced architecture, lightning-fast data sync, and plug-and-play compatibility, it transforms complexity into clarity. Whether you're scaling up or starting smart, this system offers the flexibility, durability, and intelligence your operations demand.In a world where precision meets pressure, the NX-ERA JET PLC ensures your plant doesn’t just perform—it excels.

Advanced PLC Automation for Smart Manufacturing

In the age of Industry 4.0, surface coating is no longer just about chemistry—it's about intelligence, precision, and adaptability. That’s where advanced PLC automation steps in as the invisible powerhouse behind your plant’s performance. Whether you're scaling up operations or streamlining a compact facility, smart automation is the lever that elevates your process from ordinary to outstanding.

Let’s uncover how Messung’s cutting-edge PLC technology is revolutionising autophoretic coating plants with flexible, responsive, and future-ready control systems.

Modular, Compact & Ready to Go - Whether it’s a big plant or a small-scale setup, our Modular PLC, Compact PLC, and Smart PLC configurations give you tailor-made flexibility.

Motion Control with Millisecond Precision - Our motion control systems enable synchronised movement, avoiding delays or overlaps in the coating sequence.

Material Handling - Our embedded material handling controllers do the heavy lifting—literally—without breaking a sweat.

This isn't just automation. This is smart automation that thinks ahead, moves with purpose, and adapts to demand. With Messung’s PLC-powered intelligence, your coating plant doesn’t just run—it evolves.

Because in the world of advanced manufacturing, it’s not just about staying ahead—it's about setting the pace.

Smart. Sustainable. Secure: The Evolution of PLC Automation in Coating Plants

In the era of Industry 4.0, coating plants need more than just control—they need intelligence, integration, and intention. Here’s how Messung’s PLC automation is redefining autophoretic coating systems:

Built for Harsh Industrial Realities – Our Industrial PLCs endure dust, moisture, heat, and vibration. Conformal-coated PLCs protect against corrosive chemicals in A-coating zones and provide long-lasting performance in extreme environments.

Safety Meets Smarts - PLCs are integrated for emergency stops, controlled shutdowns, and real-time fault alerts with logs, making them smart, secure, and always in control.

Welcome to Industry 4.0-Based Controllers

PLC with IoT for remote monitoring and real-time plant access.

MQTT-based PLCs for cloud-friendly, lightweight data communication.

Full PLC system integration with BMS, SCADA & more—ensuring a harmonious automation ecosystem.

Green Gains: Eco-Friendly A-Coating Automation

Water-based chemistry reduces VOCs and emissions.

Smart PLCs optimize dosing & disposal—minimising waste, maximising results.

Cleaner air, cleaner conscience, smarter coatings.

With Messung’s intelligent PLC, you don’t just automate—you evolve. Sustainable, scalable, and secure—this is the new face of PLC-based automation solutions in A-coating.

Business Benefits of PLC-Based Automation Solutions

In today’s hyper-competitive manufacturing world, success isn’t just about innovation—it’s about consistency, efficiency, and scalability. This is where PLC-based automation doesn’t just support your coating process—it transforms it. Let’s explore how Messung’s smart automation systems turn operational goals into tangible business advantages.

Uniformity Every Time - When every product must meet the same high standard, there’s no room for guesswork. Thanks to PLC control systems, your coating process is even, repeatable, and of high quality. 

Never any Downtime - Time is money, and downtime is a thief. With real-time monitoring and intelligent automation controllers, potential issues are detected and resolved before they affect production. Fewer breakdowns. More uptime. Happier bottom line.

Easy to Maintain & Scale - Growth shouldn’t be a gamble. With built-in PLC maintenance alerts, you get proactive notifications that prevent surprises. Want to expand operations? Simply plug and play with modular I/O modules. You’re ready for tomorrow—today.

In essence, PLC automation is not just a control system—it’s a business strategy. It safeguards quality, boosts efficiency, and equips your coating plant with the agility to evolve. Because when your process is smart, your performance is unstoppable.

Conclusion: The Final Coat

A surface is only as strong as the system behind it. In the era of smart manufacturing, Messung’s PLC automation solutions empower autophoretic coating plants with unmatched precision, efficiency, and sustainability. From real-time monitoring and advanced PLC control systems to seamless IoT integration and predictive maintenance, our technology ensures optimal surface protection with minimal waste. Whether it’s modular PLCs, industrial automation controllers, or motion control systems, Messung delivers the complete package. So why let inefficiencies corrode your bottom line? Upgrade your coat. Upgrade your process. Upgrade with Messung PLCs—where intelligent automation meets perfect protection.

FAQs

How does PLC contribute to energy efficiency in coating plants?

By optimizing process timings, reducing idle machine hours, and enabling intelligent power management, PLCs help cut down energy consumption and operational costs.

Can PLC automation reduce coating defects?

Absolutely. With real-time monitoring, precision control, and error alerts, PLC automation ensures consistent quality.

How easy is it to integrate Messung PLCs in existing lines?

Very! Our modular PLC systems and versatile PLC communication protocols like MODBUS and TCP/IP allow seamless integration.

Are conformal-coated PLCs necessary?

Yes, especially in chemically aggressive environments like coating plants. They extend the life and reliability of your Programmable Logic Controller.

What industries benefit most from PLC with IoT?

Automotive, general manufacturing, and any industry embracing Industry 4.0-based controllers and smart factory setups.

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