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.

08/15/2004


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 & systems36%
AC motors (including brushless)33%
Control valves (throttling valves), actuators, and related accessories33%
Photoelectric & proximity sensors31%
Adjustable speed (variable frequency) drives (ac, dc)31%
PC-based control software28%
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 starters23%
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 accessories21%
DC motors18%
Solid-state motor starters17%
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 recorders14%
Step motors & related controls12%
Vision system software & hardware components11%
Advanced optimization software & related computing hardware10%
Robotic system hardware, software, and related devices8%
None of the above29%


Sensors and/or transmitters

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
ABB$339,25010197%11.2
Ametek$23,8005964%9.8
Anderson$22,1506843%17.0
Ashcroft$63,95094107%9.4
Druck$4,100621%3.0
Emerson Process Management$1,401,5008583022%28.6
Endress+Hauser$161,000881410%6.3
Flowline$6,1401232%4.0
Honeywell$183,9252251813%12.5
ifm efector$75,5675131713%30.2
Invensys Production Management$97,3008075%11.4
Johnson Controls$4,7001664%2.7
K-Tek$30,5002054%4.0
Magnetrol$4,900443%1.0
Masoneilan$9,0001011%10.0
Milltronics (Siemens)$19,2501775%2.4
Omega Engineering$39,5501632216%7.4
Sensotec$3,300721%3.5
Siemens/Moore$6,6501332%4.3
Wika Instrument$5,0002011%20.0
Yokogawa$142,5004364%7.2
Other$257,73725773526%73.6


Programmable logic controllers (PLC) hardware & software

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
AutomationDirect$30,450311212%2.6
Baldor Electric$6,500211%2.0
Emerson Process Management$62,0001122%5.5
GE Fanuc$646,9001341313%10.3
Mitsubishi Electric$19,140744%1.8
Moeller$18,0001122%5.5
Omron Electronics$64,1001033%3.3
Opto 22$1,500511%5.0
Rockwell Automation/Allen-Bradley$4,115,2767617875%9.8
Schneider Electric$430,8001221313%9.4
Siemens$810,000991111%9.0
Other$207,10013866%23.0


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

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
Acromag$24,5001623%8.0
Ametek$23,0003023%15.0
AutomationDirect$2,5002145%5.3
Banner Engineering$109,100202668%337.7
Bindicator$3,050534%1.7
CCS Dual Snap(Custom Control Sensors)$700111%1.0
Eaton Electrical/ Cutler-Hammer$3,6001023%5.0
Drexelbrook$13,7002434%8.0
Dwyer Instruments$27,5001991317%15.3
Emerson Process Management$8,0005834%19.3
Endress+Hauser$8,9001334%4.3
Flow-Tek$675611%6.0
Fluid Components International$15,4501445%3.5
Gems$4,000623%3.0
Honeywell$7,6004857%9.6
ifm efector$7,9501757%3.4
Invensys Production Management$300211%2.0
Magnetrol$11,0001545%3.8
McDonnell & Miller$300211%2.0
Micro Switch (Honeywell)$4,8955957%11.8
Moeller$200211%2.0
Omega Engineering$17,300911013%9.1
Pepperl+Fuchs$1,000211%2.0
Rockwell Automation/ Allen-Bradley$27,200217811%27.1
Schneider Electric$7,6905745%14.3
Siemens$6,800623%3.0
Sor$5,7001034%3.3
Turck$16,00014645%36.5
United Electric$27,30010168%16.8
Westlock$8,7003523%17.5
Other$44,2752361115%21.5


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

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
Dezurik$33,5005834%19.3
Durco (Flowserve)$20,0002011%20.0
Emerson Process Management$3,605,10015002738%55.6
Fluid Tech$2,000111%1.0
Honeywell$344,0004601217%38.3
Jamesbury (part of Metso Automation)$1,100,000343710%49.0
Masoneilan$205,4504346%10.8
Samson$15,0001011%10.0
Tri-Clover (Alfa Laval)$13,5001046%2.5
Tyco$160,0007034%23.3
Valtek$558,00024811%28.0
Other$10,617,59052502231%238.6


I/O products & systems

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
ABB$11,2002123%10.5
AutomationDirect$5,2501468%2.3
Bosch Rexroth$5,000111%1.0
GE Fanuc$160,800375912%41.7
Honeywell$37,0003411%34.0
Invensys Production Management$10,000511%5.0
Mitsubishi Electric$500111%1.0
National Instruments$49,200261216%2.2
Omron Electronics$11,0001656%3.2
Rockwell Automation/Allen-Bradley$674,35010553849%27.8
Schneider Electric$925,80011051216%92.1
Siemens$8,4751445%3.5
Other$120,900161810%20.1


AC motors (including brushless)

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
AO Smith$1,200311%3.0
Baldor Electric$257,0955363957%13.7
Bosch Rexroth$3,000311%3.0
Danaher Motion$600511%5.0
Grainger$19,745581218%4.8
Leeson Electric$41,600125710%17.9
Lincoln Electric$4,500734%2.3
Marathon Electric$11,1501457%2.8
Nord$1,000111%1.0
Oriental Motor$20,0007134%23.7
Rockwell Automation/Allen-Bradley$251,5001831421%13.1
Siemens$102,3005634%18.7
Sumitomo$13,6001623%8.0
TECO-Westinghouse$42,6003457%6.8
Toshiba$700111%1.0
Emerson Motor Technologies/US Motors$1,800323%1.5
Other$644,40011181218%93.2


PC-based control software

Total Dollars Total Units Respondents % of Total Respondents Avg. units per resp.
Eaton Electrical/Cutler-Hammer$1,400212%2.0
Emerson Process Management$105,0002123%10.5
Entivity$3,000112%1.0
GE Fanuc$128,60021610%3.5
Honeywell$41,000423%2.0
Iconics$9,000223%1.0
Invensys Production Management$2,275,500260610%43.3
National Instruments$68,650201526%1.3
Phoenix Contact$800112%1.0
Rockwell Automation/Allen-Bradley$319,800481628%3.0
Schneider Electric$750,000100012%1000.0
Siemens$320,5002447%6.0
Other$190,89540814%5.0





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