Walk into any factory or processing plant today, and you’re likely to find a Programmable Logic Controller (PLC) silently running the show. These industrial workhorses have been around for over 50 years—reliable, robust, and custom-built for automation tasks. But as we step into 2025, a question looms large: Are PLCs becoming obsolete?
The short answer: No, but they are evolving.
The Legacy and the Limitations
Let’s not sugarcoat it—PLCs have limitations. They were designed in an era when closed-loop systems, real-time control, and ruggedised hardware were the priority. But with modern industrial operations increasingly relying on cloud integration, AI processing, and real-time analytics, we’re now seeing PLCs becoming obsolete for many advanced use cases.
According to a report by ARC, PLCs are being challenged by more flexible, data-rich systems like Programmable Automation Controllers (PACs) and Industrial PC (IPCs). These alternatives offer more memory, higher processing power, and seamless integration with modern software ecosystems.
But does that mean PLCs are done for?
2025: Not the End, But a Turning Point
Rather than viewing 2025 as the year of PLCs becoming obsolete, it’s more accurate to see it as the inflexion point—a time when PLCs are being reimagined to fit into Industry 4.0 and even Industry 5.0 landscapes.
Here’s why PLCs are far from obsolete:
1. PLCs Are Getting Smarter
Leading manufacturers like Siemens, Rockwell Automation, and Schneider Electric are rolling out PLCs that now support edge computing, remote diagnostics, and even AI-based fault detection. For instance, Siemens’ SIMATIC S7 series now offers cloud connectivity and predictive analytics capabilities.
2. Hybrid Architectures Are the Future
We’re moving toward hybrid automation architectures, where traditional PLCs work alongside cloud-based systems. Think of it as the brain (cloud/AI) and the reflexes (PLCs) working in sync. This cyber-physical fusion allows industries to maintain the real-time responsiveness of PLCs while also gaining the big-picture insights from cloud analytics—challenging the notion of PLCs becoming obsolete by instead evolving their role within smarter, connected systems.
3. Cybersecurity and Reliability Still Favour PLCs
Despite the hype around Industrial IoT and AI, many industrial environments still prioritise deterministic control and cybersecurity. PLCs—especially when isolated from broader networks—are inherently more secure and reliable than open, internet-connected systems.
According to ISA Global Cybersecurity Alliance, protecting critical infrastructure requires a layered, secure-by-design approach, which PLCs still help facilitate.
4. Workforce Familiarity Matters
There’s a massive installed base of technicians, engineers, and plant managers who are trained on PLC systems. However, with PLCs becoming obsolete in many areas, rather than undergoing an expensive, risky transition, many businesses are opting for incremental upgrades to smarter PLC platforms.
Final Thoughts
Are PLCs becoming obsolete? No.
Are they changing? Absolutely.
Think of it not as a funeral for old tech, but a renaissance for industrial automation.
And the best part? You don’t have to choose between old and new. The future belongs to companies that can integrate both worlds seamlessly balancing the reliability of PLCs with the agility of next-gen tech.
