Programmable Logic Controller (PLC)

Programmable Logic Controller (PLC) or programmable controller is an electronic component of an industrial controller, a specialized (computerized) device used to automate technological processes. The main mode of long-term operation of PLC, often in adverse environmental conditions, is its autonomous use, without serious maintenance and practically without^[1] intervention^[1]

Computer numerical control (CNC) systems are sometimes built on PLCs. PLCs are real-time devices.

Unlike

• microcontroller (single-chip computer), microcircuit designed to control electronic devices, PLC applications are usually automated industrial processes, in the context of a manufacturing enterprise;
• computers, PLCs have developed I/O devices for sensor signals and actuators as opposed to weak control I/O capabilities (keyboard, mouse, monitor, etc.);
• embedded systems - PLC is installed separately from the equipment controlled by it.

The first logic controllers appeared in the form of cabinets with a set of interconnected relays and contacts. This scheme was set harshly at the design stage and could not be changed further.

The world's first PLC, MOdular DIgital CONtroller (Modicon) 084, which has 4 kB memory, was produced in 1968.

In the first PLCs that replaced conventional logic controllers, the connection logic was programmed with a LD (Ladder logic Diagram) connection scheme. The device had the same principle of operation, but relays and contacts (except input and output) were virtual, that is, they existed in the form of a program executed by the PLC microcontroller. Modern PLCs are "freely programmable."

In process object control systems, logic commands prevail over numerical operations, which allows, with the comparative simplicity of a microcontroller (buses with a width of 8 or 16 bits), to obtain powerful systems operating in real time. In modern PLCs, numerical operations are implemented on a par with logical ones. At the same time, unlike most computer processors, the PLC provides access to individual memory bits.

Market estimates

2024

Sales of programmable logic controllers in Russia for the year reached 18.2 billion rubles

The volume of the Russian market for industrial programmable logic controllers (PLC) in 2024 amounted to 18.2 billion rubles. The industry is showing steady positive dynamics, as stated in a study by J'son & Partners Consulting, the results of which TAdviser got acquainted with in early February 2026.

PLC is a digital electronic device based on an industrial class microcontroller that operates in real time, uses programmable memory to store instructions for controlling various types of machines or processes using digital or analog I/O modules. In this case, programmable logic is used to perform the required functions, transform, process and store information received from connected sensors and other devices, and then generate and execute control commands for certain mechanisms.

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Фото: Freepik

The authors of the study consider industrial PLCs, which are a key element of "heavy" APCS (automated process control systems). Among the main areas of application of such solutions are power, oil and gas, chemical and petrochemical industries, metallurgy and heavy industry, mining, complex continuous technological processes (DCS systems). Industrial PLCs as a key component of APCS are widely used in systems of various sizes and purposes. With a single functional role, such solutions differ significantly in architecture, parameters, redundancy level, design and other parameters.

According to J'son & Partners Consulting, more than 30 companies are engaged in the production of industrial PLCs in Russia. These include Prosoft Systems, Incomsistem, Elara, Nefteavtomatika, Tekongrup, Aries and others. Most vendors combine PLC, I/O, and other products with software development, engineering, and integration.

In order to analyze the main technical characteristics of PLCs presented on the Russian market, J'son & Partners Consulting experts analyzed 827 PLC models from 99 manufacturers, of which more than half are represented by Russian companies, which reflects the impact of import substitution and sanctions restrictions, the report says.

Fortune Business Insights analysts predict that in the future, the CAGR in the market under consideration will be 9%. Thus, by 2030, sales of industrial PLCs in Russia may increase to 30.1 billion rubles. Growth factors are large-scale import substitution, forcing the transition to domestic components, the mandatory use of trusted software and hardware systems at critical information infrastructure (CII) facilities, as well as the need to modernize APCS. At the same time, experts point to a number of difficulties faced by industry participants. One of the problems is the continued dependence on the foreign electronic component base. Additional difficulties create incompatibility of devices with each other, limited production capacity and lack of personnel.

The study also says that the total volume of the Russian PLC market (taking into account industrial devices and products for other applications) in 2024 reached 47.8 billion rubles in monetary terms. Thus, industrial class models account for approximately 38% of total costs.^[2]

Up to $11.96 billion in programmable logic controller sales

In 2024, the global programmable logic controller (PLC) market reached $11.96 billion. More than a third of this amount was provided by the Asia-Pacific region. Industry trends are addressed in the Fortune Business Insights survey presented in early November 2025.

PLCs are specialized electronic devices designed for automation and control of technological processes in industry, power and other areas. Such products are developed with an eye to long-term and stable operation - including in adverse conditions. PLCs can be reprogrammed and customized for specific tasks, add new features, and adapt to changing conditions without modifying the hardware. These products are used to control machines, robots, conveyor lines, pumping stations and other technological installations, as well as all kinds of equipment for a smart home, security systems, etc. PLCs can be integrated with MES, SCADA and ERP complexes.

Among the key factors of market growth, the authors of the study call the development of the concept of "Industry 4.0" (the fourth industrial revolution) and the ongoing digital transformation of enterprises in various fields. PLCs automate processes, improve the quality and security of operations, and provide diagnostics and remote monitoring of equipment.

Another driver of the industry is the desire of enterprises to reduce costs. PLCs improve processes, improve reliability of process units, and reduce downtime to minimize costs. PLC automation reduces maintenance costs, labor and resources, and reduces production costs.

Among the restraining factors is the difficulty of integrating PLCs with existing systems. In addition, due to the formed geopolitical situation and a change in duties, prices for electronic components may increase, which increases the final cost of PLC.

Analysts segment the market into hardware solutions (processors, memory chips, power supplies, communication modules, etc.), software and services. In 2024, the first of these sectors provided the largest share of revenue - $7.06 billion. In terms of application, the automotive industry, the production of food and drinks, power and utilities, pharmaceuticals, etc., are distinguished. The automotive segment is in the lead with $4.35 billion. Geographically, Asia-Pacific dominates with 38.8%, or $4.64 billion. Globally, major industry players are:

• Siemens AG;
• Rockwell Automation;
• Schneider Electric SE;
• Mitsubishi Electric;
• ABB;
• Ormron;
• Honeywell International;
• Emerson Electric;
• Bosch Rexroth AG;
• Hitachi;
• Panasonic Industry;
• Delta Electronics;
• Fuji Electric;
• Idec Corporation;
• General Electric.

In 2025, the PLC market size is expected to reach $12.66 billion. The United States, according to estimates, will have $2.57 billion, Europe - $2.55 billion, Asia-Pacific - $4.95 billion. Fortune Business Insights analysts believe that in the future, the CAGR will be 6.43%. Thus, by 2032, costs may increase to $19.58 billion.^[3]

Growth of the volume of the Russian PLC market to 15 billion rubles

At the end of 2024, the volume of the Russian market for programmable logic controllers (PLC) for industrial applications amounted to about 15 billion rubles. This is stated in a study by J'son & Partners Consulting, the results of which were published in mid-December 2024.

By PLC analytics is meant a digital electronic device based on an industrial class microcontroller that operates in real time, uses programmable memory to store instructions for controlling various types of machines or processes using digital or analog I/O modules. Such a solution uses programmable logic to perform the required functions, convert, process and store information received from connected sensors and other devices, and then generate and execute control commands for the actuators.

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Фото: Freepik

The study says that the Russian PLC market for industrial automation is one of the most diversified segments of the market for solutions for APCS (automated process control system). Despite the continued dominance of foreign brands in many industries, a number of segments, such as energy generation and distribution, did not allow foreign solutions. Against this background, such large PLC manufacturers as Tekon, Prosoft-Sistema, Quint, Teploautomatika, Elara and others appeared in the Russian Federation. In general, as of 2024, about 30 domestic PLC manufacturers operate in the Russian Federation, most of which offer products of different classes that differ in their consumer qualities.

According to experts, the available variety of models of domestic PLCs is sufficient to meet the basic needs of industrial customers. However, the performance and functionality of Russian PLCs, as stated in the study, does not fully meet the needs of industrial customers. Analysts of J'son & Partners Consulting highlight several main problems of the PLC market in Russia:

• Limited production capacity;
• Dependence on the supply of foreign electronic components, especially high-performance processors;
• Shortage of qualified personnel;
• Incompatibility of solutions of various manufacturers;
• A large proportion of "inherited" Western proprietary solutions in industry.

The bottleneck is the completeness of the supply of systems. Customers are accustomed to the fact that the vendor supplies PLC and PLC SIS, which are integrated into one user-friendly system. Now you can buy an ESD system from Russian suppliers, but it will not be integrated with a common system. And the common system is not as user-friendly as Western vendors had, the study said.

At the same time, according to experts, in the conditions of the formed geopolitical situation, the Russian PLC market will demonstrate stable positive dynamics. The CAGR (average annual growth rate in complex percentages) in the period from 2024 to 2030 is predicted at 10%. The share of domestic equipment is expected to increase against the background of state support for Russian manufacturers and in the context of limited access to foreign solutions and technologies. It is said that the opened market opportunities for Russian manufacturers largely compensate for the existing problems and restrictions: most of the main industrial consumers are ready to switch to domestic software and hardware solutions for APCS by 2030-2035.^[4]

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