US process automation market to exceed $54 billion by 2035

PEX Network’s key takeaways:

• The US process automation market is showing strong growth and is projected to exceed US$54 billion by 2035.
• This growth is supported by an increasing emphasis on operational efficiency, cost optimization, and enhanced process reliability.
• A key trend shaping the US process automation market is the integration of digital technologies such as artificial intelligence (AI), machine learning, and the industrial internet of things (IIoT).

The US process automation market is projected to exceed $54 billion by 2035 having reached a value of $32.82 billion in 2025. That’s according to a report from Expert Market Research.

The market is experiencing steady growth, driven by the rising adoption of automation technologies across industries such as manufacturing, energy, chemicals, pharmaceuticals, and food and beverages.

This growth is further supported by an increasing emphasis on operational efficiency, cost optimization, and enhanced process reliability. As a result, the market is expected to expand at a CAGR of 5.20 percent from 2026 to 2035.

Meanwhile, separate research from IBM found that businesses view AI agents as essential tools in process automation.

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AI is shaping the US process automation market

One of the key trends shaping the US process automation market is the increasing integration of digital technologies such as AI, machine learning, and the IIoT, the report stated.

These technologies enable real-time data collection, predictive maintenance, and advanced analytics, thereby enhancing decision-making and process efficiency. The growing adoption of smart factories and industry 4.0 initiatives is further accelerating the deployment of advanced automation solutions.

Another key trend is the growing preference for cloud-based, software-driven automation platforms. Organizations are moving toward scalable, flexible systems that support remote monitoring, easy integration with existing infrastructure, and continuous upgrades.

At the same time, increased focus on energy efficiency and sustainability is driving industries to adopt automation solutions that improve resource efficiency and lower environmental impact.

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Growth drivers in the US process automation market

The primary driver of growth in the US process automation market is the increasing need to improve operational efficiency while reducing labor costs. Automation helps organizations streamline complex processes, minimize human error, and enhance overall productivity, making it a critical investment for industries facing rising operational expenses.

The increasing complexity of industrial operations, along with stricter regulatory requirements, is further driving market growth. Sectors such as pharmaceuticals, chemicals, and food processing demand accurate process control and adherence to rigorous quality and safety standards, which automation systems are well suited to deliver.

Elsewhere, skill shortages across several industrial sectors are encouraging companies to implement automated solutions to ensure consistent and uninterrupted production.

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Challenges and opportunities in the US process automation market

Despite its strong growth prospects, the process automation market encounters challenges including high upfront investment requirements and difficulties integrating with legacy systems, according to Expert Market Research.

Small and medium-sized enterprises, in particular, may be reluctant to adopt automation due to limited budgets and uncertainty around return on investment.

In contrast, these challenges are creating significant opportunities for technology providers. The development of modular, cost-effective, and user-friendly automation solutions is making automation more accessible to a wider range of businesses.

What’s more, the increasing focus on security and secure automation systems presents opportunities for vendors offering robust and compliant solutions tailored to the evolving industrial landscape.

All Access: Future of BPM 2026

You asked, and we listened. Business process management (BPM) remains the cornerstone technology for driving organizational transformation, according to the survey results featured in the latest PEX Report. As we look toward 2026 and beyond, generative AI, agentic AI, and intelligent process orchestration are redefining how processes are designed, executed, and optimized. BPM is your key to adapting swiftly and effectively in this new era.

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