Control Engineering’s Buyers Guide 2004 Purchasing Study

To gain a better understanding of industry buying power, Control Engineering and Reed Research Group surveyed Control Engineering subscribers about purchases across 26 product categories to determine numbers of units purchased in the past 12 months as well as how much was spent on those purchases.

By Staff August 15, 2004

To gain a better understanding of industry buying power, Control Engineering and Reed Research Group surveyed Control Engineering subscribers about purchases across 26 product categories to determine numbers of units purchased in the past 12 months as well as how much was spent on those purchases. The full survey, available at Control Engineering ‘s Resource Center, / , also shows average cost per unit and most preferred vendors.

Leading categories of “products purchased” are sensors and/or transmitters (flow, level, temperature, pressure, etc.), programmable logic controllers (PLC) hardware and software, switches (flow, level, temperature, pressure, etc.), I/O products and systems, and ac motors (including brushless).

The survey, conducted in late January 2004, received more than 750 responses from subscribers—56% percent manage as many as 20 employees—with the following job function breakdown:

  • Control and/or instrument engineering: 19%;

  • Systems design engineering including applied R&D: 13%;

  • Other engineering, including product, software, plant, electrical and/ or electronic: 12%;

  • Systems integrators and/or consultants: 12%;

  • General or corporate management: 10%;

  • Operations and/or maintenance: 10%;

  • Product design engineering including applied R&D: 9%;

  • Production engineering, process or manufacturing: 9%;

  • Evaluation, quality control, standards, reliability, test engineering: 4%; and

  • Basic research: 1%

The following tables illustrate purchasing levels across the 26 product categories surveyed as well as details on specific categories: sensors and/or transmitters (flow, level, temperature, pressure, etc.); programmable logic controllers hardware and software; switches (flow, level, temperature, pressure, etc.); I/O products and systems; AC motors (including brushless); control valves (throttling valves), actuators, and related accessories; and PC-based control software.

Products purchased

Switches (flow, level, temperature, pressure, etc.) 37%
I/ O products & systems 36%
AC motors (including brushless) 33%
Control valves (throttling valves), actuators, and related accessories 33%
Photoelectric & proximity sensors 31%
Adjustable speed (variable frequency) drives (ac, dc) 31%
PC-based control software 28%
HMI/ SCADA software & operator interface hardware (including PCs) 27%
Motion controller and/ or positioner hardware & software, including feedback devices (encoders, resolvers, tachometers, torque sensors, etc.) 26%
Electromechanical motor starters 23%
Data acquisition (DAQ) equipment hardware & software, including remote terminal units (RTUs) 23%
Distributed and/or hybrid control systems (hardware & software) 23%
Single & multi-loop controllers (including stand-alone) 23%
Servo motors (ac, dc, brushless) 22%
Block (on/ off) valve, actuators, and related accessories 21%
DC motors 18%
Solid-state motor starters 17%
Power elements for motor control (power modules, power switching devices, etc.) 16%
Process analyzers (pH, CO 2 , chromatography, CO, etc.) 16%
Paper and/ or paperless recorders 14%
Step motors & related controls 12%
Vision system software & hardware components 11%
Advanced optimization software & related computing hardware 10%
Robotic system hardware, software, and related devices 8%
None of the above 29%

Sensors and/or transmitters

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
ABB $339,250 101 9 7% 11.2
Ametek $23,800 59 6 4% 9.8
Anderson $22,150 68 4 3% 17.0
Ashcroft $63,950 94 10 7% 9.4
Druck $4,100 6 2 1% 3.0
Emerson Process Management $1,401,500 858 30 22% 28.6
Endress+Hauser $161,000 88 14 10% 6.3
Flowline $6,140 12 3 2% 4.0
Honeywell $183,925 225 18 13% 12.5
ifm efector $75,567 513 17 13% 30.2
Invensys Production Management $97,300 80 7 5% 11.4
Johnson Controls $4,700 16 6 4% 2.7
K-Tek $30,500 20 5 4% 4.0
Magnetrol $4,900 4 4 3% 1.0
Masoneilan $9,000 10 1 1% 10.0
Milltronics (Siemens) $19,250 17 7 5% 2.4
Omega Engineering $39,550 163 22 16% 7.4
Sensotec $3,300 7 2 1% 3.5
Siemens/Moore $6,650 13 3 2% 4.3
Wika Instrument $5,000 20 1 1% 20.0
Yokogawa $142,500 43 6 4% 7.2
Other $257,737 2577 35 26% 73.6

Programmable logic controllers (PLC) hardware & software

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
AutomationDirect $30,450 31 12 12% 2.6
Baldor Electric $6,500 2 1 1% 2.0
Emerson Process Management $62,000 11 2 2% 5.5
GE Fanuc $646,900 134 13 13% 10.3
Mitsubishi Electric $19,140 7 4 4% 1.8
Moeller $18,000 11 2 2% 5.5
Omron Electronics $64,100 10 3 3% 3.3
Opto 22 $1,500 5 1 1% 5.0
Rockwell Automation/Allen-Bradley $4,115,276 761 78 75% 9.8
Schneider Electric $430,800 122 13 13% 9.4
Siemens $810,000 99 11 11% 9.0
Other $207,100 138 6 6% 23.0

Switches (flow, level, temperature, pressure, etc.)

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
Acromag $24,500 16 2 3% 8.0
Ametek $23,000 30 2 3% 15.0
AutomationDirect $2,500 21 4 5% 5.3
Banner Engineering $109,100 2026 6 8% 337.7
Bindicator $3,050 5 3 4% 1.7
CCS Dual Snap(Custom Control Sensors) $700 1 1 1% 1.0
Eaton Electrical/ Cutler-Hammer $3,600 10 2 3% 5.0
Drexelbrook $13,700 24 3 4% 8.0
Dwyer Instruments $27,500 199 13 17% 15.3
Emerson Process Management $8,000 58 3 4% 19.3
Endress+Hauser $8,900 13 3 4% 4.3
Flow-Tek $675 6 1 1% 6.0
Fluid Components International $15,450 14 4 5% 3.5
Gems $4,000 6 2 3% 3.0
Honeywell $7,600 48 5 7% 9.6
ifm efector $7,950 17 5 7% 3.4
Invensys Production Management $300 2 1 1% 2.0
Magnetrol $11,000 15 4 5% 3.8
McDonnell & Miller $300 2 1 1% 2.0
Micro Switch (Honeywell) $4,895 59 5 7% 11.8
Moeller $200 2 1 1% 2.0
Omega Engineering $17,300 91 10 13% 9.1
Pepperl+Fuchs $1,000 2 1 1% 2.0
Rockwell Automation/ Allen-Bradley $27,200 217 8 11% 27.1
Schneider Electric $7,690 57 4 5% 14.3
Siemens $6,800 6 2 3% 3.0
Sor $5,700 10 3 4% 3.3
Turck $16,000 146 4 5% 36.5
United Electric $27,300 101 6 8% 16.8
Westlock $8,700 35 2 3% 17.5
Other $44,275 236 11 15% 21.5

Control valves (throttling valves), actuators, and related accessories

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
Dezurik $33,500 58 3 4% 19.3
Durco (Flowserve) $20,000 20 1 1% 20.0
Emerson Process Management $3,605,100 1500 27 38% 55.6
Fluid Tech $2,000 1 1 1% 1.0
Honeywell $344,000 460 12 17% 38.3
Jamesbury (part of Metso Automation) $1,100,000 343 7 10% 49.0
Masoneilan $205,450 43 4 6% 10.8
Samson $15,000 10 1 1% 10.0
Tri-Clover (Alfa Laval) $13,500 10 4 6% 2.5
Tyco $160,000 70 3 4% 23.3
Valtek $558,000 24 8 11% 28.0
Other $10,617,590 5250 22 31% 238.6

I/O products & systems

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
ABB $11,200 21 2 3% 10.5
AutomationDirect $5,250 14 6 8% 2.3
Bosch Rexroth $5,000 1 1 1% 1.0
GE Fanuc $160,800 375 9 12% 41.7
Honeywell $37,000 34 1 1% 34.0
Invensys Production Management $10,000 5 1 1% 5.0
Mitsubishi Electric $500 1 1 1% 1.0
National Instruments $49,200 26 12 16% 2.2
Omron Electronics $11,000 16 5 6% 3.2
Rockwell Automation/Allen-Bradley $674,350 1055 38 49% 27.8
Schneider Electric $925,800 1105 12 16% 92.1
Siemens $8,475 14 4 5% 3.5
Other $120,900 161 8 10% 20.1

AC motors (including brushless)

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
AO Smith $1,200 3 1 1% 3.0
Baldor Electric $257,095 536 39 57% 13.7
Bosch Rexroth $3,000 3 1 1% 3.0
Danaher Motion $600 5 1 1% 5.0
Grainger $19,745 58 12 18% 4.8
Leeson Electric $41,600 125 7 10% 17.9
Lincoln Electric $4,500 7 3 4% 2.3
Marathon Electric $11,150 14 5 7% 2.8
Nord $1,000 1 1 1% 1.0
Oriental Motor $20,000 71 3 4% 23.7
Rockwell Automation/Allen-Bradley $251,500 183 14 21% 13.1
Siemens $102,300 56 3 4% 18.7
Sumitomo $13,600 16 2 3% 8.0
TECO-Westinghouse $42,600 34 5 7% 6.8
Toshiba $700 1 1 1% 1.0
Emerson Motor Technologies/US Motors $1,800 3 2 3% 1.5
Other $644,400 1118 12 18% 93.2

PC-based control software

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
Eaton Electrical/Cutler-Hammer $1,400 2 1 2% 2.0
Emerson Process Management $105,000 21 2 3% 10.5
Entivity $3,000 1 1 2% 1.0
GE Fanuc $128,600 21 6 10% 3.5
Honeywell $41,000 4 2 3% 2.0
Iconics $9,000 2 2 3% 1.0
Invensys Production Management $2,275,500 260 6 10% 43.3
National Instruments $68,650 20 15 26% 1.3
Phoenix Contact $800 1 1 2% 1.0
Rockwell Automation/Allen-Bradley $319,800 48 16 28% 3.0
Schneider Electric $750,000 1000 1 2% 1000.0
Siemens $320,500 24 4 7% 6.0
Other $190,895 40 8 14% 5.0