The global machine condition monitoring market size is expected to reach USD 5.46 billion by 2030, according to a new report by Grand View Research, Inc. The industry is anticipated to grow at a lucrative CAGR of 7.9% from 2023 to 2030. Exponential demand for monitoring services to avoid machinery failure will propel the penetration of condition-monitoring systems. End-users have exhibited an unprecedented demand for predictive maintenance tools to bolster asset life, minimize machine failure and reduce maintenance costs. Stakeholders envisage revenue-boosting potentials in maintaining machine health and reducing downtime with advanced software and tools. The emergence of the Industrial Internet of Things (IIoT) has propelled the measurements, such as pressure, vibration, and temperature.
Machine condition monitoring helps measure equipment, enhance production efficiency, and reduce unplanned downtime. Industrial IoT has provided promising growth potential following the growing footfall of smart sensors across North America, Europe, and the Asia Pacific. Leading companies are poised to prioritize vibration, torque, and temperature monitoring to foster monitoring processes. For instance, vibration diagnosis has gained ground to boost the detection of possible faults, mainly due to the adoption of IoT technology and advanced algorithms.
Gather more insights about the market drivers, restrains and growth of the Machine Condition Monitoring Market
Detailed Segmentation:
Market Dynamics
The widespread adoption of wireless technology in machine condition monitoring is revolutionizing industries by providing an affordable and easily implementable solution. Wireless sensors enable real-time monitoring, offering operators a comprehensive overview of machine health. This proactive approach allows for early problem identification and resolution, preventing costly downtime. The cost-effectiveness of wireless solutions, attributed to their avoidance of complex wiring infrastructure, significantly benefits small and medium-sized businesses, making this technology an accessible option.
Monitoring Technique Insights
The vibration monitoring segment led market in 2022, accounting for over 26% share of global revenue. The high share can be attributed to soaring demand to detect wear, imbalances, and misalignments. Rising penetration of monitoring vibration has played a pivotal role in offering insights into detecting faults at an early stage. Vibration monitoring solutions have witnessed an uptick in minimizing maintenance, integration, and operational complexities. Industry players have increased investments in continuously monitoring equipment, including cooling tower gearboxes, boiler feed pumps, steam turbines, and gas. End-users will likely embed vibration monitoring into their system to foster reliability and protect data. Technology will remain highly sought-after for diagnosing emerging issues and robust troubleshooting.
Component Insights
The hardware segment led the market in 2022, accounting for over 55% share of the global revenue. The high share can be attributed to increasing use of infrared sensors, ultrasonic detectors, vibration analyzers, and accelerometers. Technologies used in condition monitoring have specialized knowledge of areas where various types of failure can occur. Hardware or sensor manufacturers offer their products in two varieties, static and dynamic, depending on the different frequencies hardware or sensors have. Additionally, this allows manufacturers to minimize machine downtime and implement successful predictive maintenance.
Product Type Insights
The motors segment led the market in 2022, accounting for over 17% of global revenue. Growth is attributed to rising demand for motors in key industries like oil and gas, automotive, and manufacturing. Ensuring motors are in their optimal condition is essential to prevent failures, boost operational efficiency, and minimize downtime, thereby driving the growth of motors segment in machine condition monitoring. As demand for motors in various industries continues to increase, motors segment is anticipated to maintain its growth trajectory in foreseeable future.
Application Insights
The turbines & generators segment led the market in 2022, accounting for over 16% of global revenue. Escalating demand for preventive maintenance in the power generation industry drives the segment's growth. These components are crucial for power plants, and early identification of potential issues through machine condition monitoring helps prevent costly outages. Segment's growth is further fueled by increasing use of renewable energy sources, necessitating advanced monitoring solutions and the adoption of predictive maintenance strategies to optimize costs and uptime. Moreover, development of new technologies, such as vibration analysis and infrared thermography, provides more accurate and detailed data on condition of turbines and generators, boosting the segment's prominence.
Architecture Type Insights
The on-premises segment led the market in 2022, accounting for over 34% of global revenue. On-premises is often managed or self-hosted and ensures organizations meet specific market requirements, enabling teams to optimize their workload and create highly customizable environments. To ensure machines are operating efficiently, engineers need the ability to keep track and monitor status and enable teams to pinpoint long running or inefficient machines easily. Furthermore, the cost-effectiveness of on-premises solutions significantly contributed to their widespread adoption. With businesses keen on budget optimization, the affordability of these solutions rendered them highly attractive, offering access to robust monitoring capabilities without straining financial resources.
Plant Type Insights
Brownfield plant segment held the largest revenue share of over 70% in 2022. This is because brownfield plants are older, nearing the end of their lifespan, and face a higher risk of failures and downtime, creating a pressing need for condition monitoring. Factors such as increased safety focus in the industrial sector, regulatory compliance requirements, and higher probability of equipment problems in older setups contribute to a larger market share for machine condition monitoring in brownfield plants. Proactive monitoring in these environments is crucial for businesses to ensure operational efficiency, minimize risks, and avoid costly disruptions.
Monitoring Process Insights
The online condition monitoring segment held the largest revenue share of over 51% in 2022. Growth is attributed to soaring demand for data monitoring and management to reduce downtime and defects and bolster machine life. Leading manufacturers are poised to prioritize advanced monitoring systems to expand penetration across untapped regions. The need for real-time metrics and alert notifications has triggered demand for online monitoring systems to boost machines' health information. For instance, in July 2022, Valmet, supplier and developer of automation systems, stated that online condition monitoring systems are typically used in industries like oil & gas, power generation, and metals & mining. Demand for online condition monitoring is high as portable monitoring procedures are challenging to use in production plants located in remote areas.
End-use Industry Insights
The power generation segment dominated the market in 2022 and accounted for a revenue share of over 15%. Growth is attributed to high failure rates for some components, such as increased repair costs, entire system overhauls, and unsafe work environments in the power and generation industry. As this industry is product-intensive, it requires continuous machinery maintenance. Further, the oil and gas segment will acquire significant market share due to bullish demand for oil analysis, thermography, and vibration monitoring. The industry has witnessed unprecedented demand for condition monitoring to keep up with demand for sensor applications to boost efficiency and productivity.
Regional Insights
North America dominated the market in 2022, accounting for over 36% share of global revenue. U.S. and Canada are slated to provide promising growth opportunities against bullish demand from power generation, aerospace, oil & gas, marine, and food & beverages industries. The trend for vibration monitoring has become pronounced for oil condition monitoring in oil and gas platform machinery lubricants. With a surge in offshore oil exploration across North America, forward-looking companies could strengthen their position in the regional market. Oil condition monitoring is poised to receive an uptick in predictive maintenance and reliability.
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Key Companies & Market Share Insights
Incumbent players and startups are poised to emphasize organic and inorganic strategies, including mergers & acquisitions, product offerings, technological advancements, innovations, and geographical expansion. Trend for predictive maintenance and growing footfall of IoT will serve as catalysts to expand their footprint across untapped areas. For instance, in February 2023, Seed Group partnered with Samotics, a provider of asset health monitoring, to introduce condition monitoring services to the Middle East. With Samotics' SAM4 technology utilizing electrical signature analysis (ESA) to monitor critical assets, the partnership aims to cater to a growing demand for advanced condition monitoring solutions in the region's thriving industrial sector.
Some of the prominent players in the global machine condition monitoring market include:
• ALS
• Emerson Electric Co.
• General Electric
• Honeywell International Inc.
• Megget PLC
• NATIONAL INSTRUMENTS CORP
• Parker Hannifin
• Rockwell Automation, Inc.
• SKF
• Schaeffler AG
Machine Condition Monitoring Market Segmentation
Grand View Research has segmented the global machine condition monitoring market based on monitoring technique, component, product type, application, architecture type, plant type, monitoring process, end-use industry, and region:
Machine Condition Monitoring Technique Outlook (Revenue, USD Billion, 2017 - 2030)
• Torque Monitoring
• Vibration Monitoring
• Oil Analysis
• Thermography
• Corrosion Monitoring
• Others
Machine Condition Monitoring Component Outlook (Revenue, USD Billion, 2017 - 2030)
• Hardware
• Portable/Handheld Condition Monitoring Units
• Software
• Services
Machine Condition Monitoring Product Type Outlook (Revenue, USD Billion, 2017 - 2030)
• Valves
• Compressors
• Turbines
• Gearbox
• Motors
• Bearings
• Couplings
• Others
Machine Condition Monitoring Application Outlook (Revenue, USD Billion, 2017 - 2030)
• HVAC Systems
• Turbines & Generators
• Material Handling
• Conveyors
• Pump Systems
• Sprockets
• Bushings & Hubs
• Control Cabinet Monitoring
• Paper Presses
• Storage Rooms
• Motor Control
• Lubricant Level Monitoring on CNC Machines
• Others
Machine Condition Monitoring Architecture Type Outlook (Revenue, USD Billion, 2017 - 2030)
• Public Cloud
• Edge Platform
• Hybrid Cloud
• On-premises
Machine Condition Monitoring Plant Type Outlook (Revenue, USD Billion, 2017 - 2030)
• Greenfield Plant
• Brownfield Plant
Machine Condition Monitoring Process Outlook (Revenue, USD Billion, 2017 - 2030)
• Online Condition Monitoring
• Portable Condition Monitoring
Machine Condition Monitoring End-use Industry Outlook (Revenue, USD Billion, 2017 - 2030)
• Mining
• Primary Metals
• Power Generation
• Automotive
• Oil & Gas
• Aerospace
• Food & Beverages
• Chemicals
• Marine
• Pharmaceutical
• Pulp & Paper
• Others
Machine Condition Monitoring Regional Outlook (Revenue, USD Billion, 2017 - 2030)
• North America
o U.S.
o Canada
o Mexico
• Europe
o U.K.
o Germany
o France
• Asia Pacific
o China
o Japan
o India
• Central & South America
o Brazil
• MEA
Order a free sample PDF of the Machine Condition Monitoring Market Intelligence Study, published by Grand View Research.