Industrial Control Transformer: An Overview
Industrial control transformers are a type of electrical
transformer that is specifically designed to provide power to control circuits
in industrial settings. These transformers are typically smaller and less
powerful than other types of transformers, such as power transformers, and they
are often used in conjunction with other electrical components to create
complex control systems.
In this essay, we will take a closer look at industrial
control transformers, including their purpose, design, and applications.
Purpose of Industrial
- The main purpose of an industrial control transformer is to
provide power to control circuits in industrial machinery and equipment.
Control circuits are the electrical systems that are used to manage the
operation of various components in machinery, such as motors, sensors,
switches, and relays.
- Control circuits require a lower voltage than the primary
power supply that is used to run the machinery itself. This is because the
components in control circuits are often more sensitive and delicate than the
larger motors and other equipment that they control.
- Industrial control transformers are designed to step down
the voltage from the primary power supply to the lower voltage required by the
control circuit. They also provide isolation between the primary power supply
and the control circuit, which helps to protect the delicate components in the
control circuit from voltage surges and other electrical disturbances.
Design of Industrial
- Industrial control transformers are typically designed to be
small and compact, with a low power output. They are often housed in a
protective enclosure, such as a metal or plastic case, which helps to prevent
damage from dust, moisture, and other environmental factors.
- The primary winding of an industrial control transformer is
connected to the primary power supply, which may be a single-phase or
three-phase AC voltage source. The secondary winding of the transformer is
connected to the control circuit, which typically operates at a lower voltage
than the primary power supply.
- The transformer is designed to step down the voltage from
the primary power supply to the lower voltage required by the control circuit.
The ratio of the number of turns in the primary winding to the number of turns
in the secondary winding determines the amount of voltage step-down that the
transformer can provide.
Industrial Control Transformers
- Industrial control transformers are used in a wide variety
of industrial applications, including manufacturing, process control, and
automation. They are often used in conjunction with other electrical
components, such as relays, switches, and sensors, to create complex control
systems that can manage the operation of machinery and equipment.
- One common application of industrial control transformers is
in motor control circuits. In these circuits, the transformer provides power to
the control circuit that manages the operation of a motor. The control circuit
may include relays, switches, and other components that can turn the motor on
and off, change its speed or direction of rotation, and protect it from damage
due to overloads or other electrical disturbances.
- Another common application of industrial control
transformers is in process control systems. In these systems, the transformer
provides power to the control circuit that manages the operation of various
sensors and actuators that are used to monitor and control industrial
processes, such as temperature, pressure, and flow rate.
Industrial control transformers are a vital component of
many industrial control systems. They provide a safe and reliable way to step
down the voltage from the primary power supply to the lower voltage required by
control circuits. With their compact size and reliable performance, industrial
control transformers are an essential tool for managing the complex machinery
and equipment that are used in modern industrial settings.
The pandemic has caused major disruptions and challenges for
the industrial control transformer sector, but it has also presented new
opportunities. COVID-19 has shed light on the importance of risk management,
preparedness, and resilience. Leading manufacturers in this sector, like
Siemens and ABB, have experienced significant supply chain constraints in
critical areas such as base metals (e.g. copper, aluminum, and steel),
plastics, semiconductors, and transportation services.
ABB faced several challenges during the pandemic, including
disruptions to workforce and operations due to quarantine measures, government
orders, facility closures, illness, travel restrictions, and the implementation
of precautionary measures. As a result, ABB experienced a decline in orders and
revenues in 2020, with orders down by 7% to USD 26.5 billion and revenues also
down by 7%. The emergence of new COVID-19 variants and the associated
uncertainties could pose future challenges to manufacturers in meeting their
manufacturing needs and may negatively impact production and shipment of
Despite these challenges, the global industrial sector has
gradually recovered thanks to progress in COVID-19 vaccination programs and the
lifting of travel restrictions. This has led to an accelerated demand for
industrial control transformers and their associated products. It is essential
that companies continue to prioritize risk management, preparedness, and
resilience to effectively respond to the ongoing challenges presented by the
Industrial Control Transformer Market Dynamics
Drivers in Industrial
Control Transformer Market
The industrial control transformer market is being driven by
the rising global demand for energy consumption across various industries.
According to the International Energy Agency (IEA), worldwide total electricity
final consumption reached 22,848 TWh in 2019, indicating a 1.7% increase from
the previous year. While the total electricity final consumption in OECD
countries decreased by 1.1% in 2019 compared to the previous year, the final
electricity consumption in non-OECD countries increased by 3.8%.
This growing demand for electricity has led to increased
electricity trade between countries, particularly in OECD Europe where
electricity imports have grown at an average annual growth rate of 3.9% since
1974. As a result, the total annual energy investment is projected to reach USD
5 trillion by 2030, which will contribute an extra 0.4% per year to the global
With investments in clean energy and energy infrastructure
expected to triple by 2030, this increase in spending has created millions of
jobs in the clean energy, engineering, manufacturing, and construction
industries. These trends are expected to drive the global GDP up by 4% in 2030,
which will increase the demand for energy management systems, clean energy, and
energy-efficient technologies. As a result, the demand for industrial control
transformers is expected to increase significantly to meet the growing demand
for energy consumption across various industries.
Industrial Control Transformer Market
The adoption of Direct Current (DC) electric power is on the
rise, due to its potential to drive economic growth, innovation, research and
development opportunities, and environmental sustainability. DC technology and
applications offer superior energy efficiency, better power quality and
reliability, and are inherently aligned with renewable and clean energy
development. DC motors and appliances offer better efficiency and power-to-size
ratio than AC motors, leading to significant energy savings.
To meet the COP 26 goal of reducing 3x more CO2 emissions by
2030, industries must shift towards renewable and low-carbon energy sources. DC
power is compatible with renewable energy sources like solar and wind power,
which produce irregular electricity and require energy storage (batteries) to
ensure a steady supply. Batteries and solar PV are fundamentally DC energy
sources, making DC a more mechanically suitable interface. Additionally, most
energy storage technologies are DC-based, leading to increased efficiencies and
decreased operational losses.
As electronic devices need DC power, eliminating AC to DC
conversion losses is crucial to encourage the shift to DC power. The need for
DC power is increasing due to the growing reliance on electronic devices, and
businesses at the "apex of the pyramid," such as server farms and
data centers, are the biggest new consumers of electricity. To guarantee 24/7
electricity availability with no downtime and to increase supply efficiency,
new advances in DC applications are spurring investment in local DC power
Despite being a crucial technology in many industries, the
demand for industrial control transformers is lower in the oil and gas sector.
The declining market trend in the oil and gas industry due to lower oil prices
is causing a tangential demand for industrial control transformers. The oil and
gas industry is a significant market for industrial control transformer
technology, and disruptions in demand from this industry can impact the market
in several ways.
Industrial Control Transformer Market
The chemical and petrochemical industry is rapidly growing
and creating numerous opportunities for various technologies, including
industrial control transformers. These transformers are highly durable, efficient,
and require minimal maintenance, making them ideal for use in a wide range of
industrial applications such as relays, timers, solenoids, and motor starter
Due to the energy-intensive nature of the chemical industry,
a constant and high power supply is critical for the production of various
chemicals, which creates a high demand for industrial control transformers.
According to a recent report by BASF, global chemical production (excluding
pharmaceuticals) is expected to grow by 3.5% in 2022, with a significantly
stronger production forecast in the US at 4.5%.
The automotive and electronics sectors in Japan are also
expected to offer strong growth opportunities, with a growth rate of 2.5% in
2022. Similarly, South America's chemical production is expected to grow at a
rate of 1.5% due to the recovery of the automotive industry and moderate growth
in demand from agriculture and the raw materials sector.
However, despite the significant demand for industrial
control transformers, the oil and gas industry has a lower demand for this
technology, which is causing a decline in the production rate of industrial
control transformers. This declining trend is due to the decreasing oil prices,
which is impacting the overall market for industrial control transformers. As
the oil and gas industry holds a major share in the industrial control
transformer market, any disruptions in demand from this sector can
significantly affect the market.
Industrial Control Transformer Market
Industrial control transformers play a crucial role in
mining operations worldwide, specifically in metals and mining applications,
such as rolling mills, hoists, blowers, and processing lines. However, the coal
mining industry faces several challenges due to increasing emission regulations
and global decarbonization goals. Coal is a highly polluting source of energy,
leading advanced economies worldwide to reduce their consumption of coal to
comply with environmental regulations. According to the International Energy
Agency, coal production in the United States is predicted to decrease by 77 MT,
and in the European Union, by 102 MT by 2024. In addition, the power sector in
these regions is expanding rapidly, with a surge in demand for renewable energy
sources such as wind and solar PV. As countries switch to using gas instead of
coal for power generation due to its lower carbon intensity, the demand for
coal is expected to decline rapidly. Consequently, this may lead to a decrease
in coal mining activity, negatively impacting the demand for industrial control
transformers in the coal mining industry.
The industrial control transformer market is being driven by
various factors, including the need for safe and smooth operations in
industries such as power generation, manufacturing, and food & beverage.
The market size of the 120 V industrial control transformer is relatively large
due to its common installation in control panels in small workspaces where low
voltages are required.
In terms of frequency, the 50 Hz industrial power control
transformer market is being driven by government regulations and standards
pertaining to power supply frequency. These transformers are widely used in
motor starters, contactors, solenoids, timer circuits, relays, and control
panels in various industrial equipment. The growth of major economies in the
Asia Pacific region, such as China, India, South Korea, Japan, Indonesia, and
Australia, is also driving the market.
According to the International Monetary Fund (IMF), the Asia
Pacific region's economy grew by 6.5% in FY2021, with expectations of further
growth of 5.7% in FY2022. Although the COVID-19 pandemic caused an economic
decline of about 1.5% in 2020, the demand for electricity in the region is
expected to have grown by 8% in 2021, from a low of 2% in 2020.
The major end users of industrial control transformers are
industrial sectors such as power generation, oil & gas, chemical &
petrochemical, and others. Despite the pandemic's impact on the global economy,
electricity generation is considered an essential service and was hence less
affected by the coronavirus pandemic in 2020.
The chemical industry is projected to be the fastest-growing
segment from 2022 to 2027, according to market analysis. Industrial power
control transformers are used in the chemical sector to regulate the movement
of fluids and semi-fluids in a manufacturing plant, such as for transporting
chemicals during production. A BASF report estimates that global chemical
production (excluding pharmaceuticals) will grow by 3.5% in 2022, which is
expected to increase sales of industrial control transformers. These
transformers are utilized in a variety of chemical production applications,
such as plastics and ammonia synthesis. The European chemical industry report
shows that China had the highest sales of around USD 1,547 billion in 2022.
Manufacturers of industrial control transformers are expected to benefit from
these developments in the chemical industry by creating new revenue streams.
The Asia Pacific region is anticipated to lead the
industrial control transformer market in terms of value and volume during the
forecast period. The region is rapidly developing, driven by major economies
such as China, India, South Korea, Japan, Indonesia, and Australia. According
to the International Monetary Fund, the region's economy grew by 6.5% in FY2021
and is projected to increase by 5.7% in FY2022, though it experienced a 1.5%
economic decline due to the COVID-19 pandemic in 2020. The power generation,
oil and gas, chemical and petrochemical sectors are the primary end-users of
industrial control transformers. In 2020, the demand for electricity was less
affected by the pandemic because it is considered an essential service. The
increased demand for electricity in the Asia Pacific region is largely driven
by China and India, with demand projected to have grown by 8% in 2021, up from
a low of 2% in 2020 according to the International Energy Agency.
Key Players in Industrial Control Transformer Market
- SCHNEIDER ELECTRIC
- GENERAL ELECTRIC
- ROCKWELL AUTOMATION, INC.
- BOARDMAN TRANSFORMERS
- MCI TRANSFORMER CORPORATION
- DONGAN ELECTRIC COMPANY
- SNC MANUFACTURING CO., INC.
- FOSTER TRANSFORMER COMPANY
- TEMCO INDUSTRIAL
- CONTROL MAGNETICS, INC.
- CUSTOM COILS
- RECO TRANSFORMERS PVT. LTD.
- TRUTECH PRODUCTS
- GRANT TRANSFORMERS
Recent Developments in Industrial Control Transformer Market
The industrial control transformer market has seen some
recent developments. In January 2022, Eaton acquired Royal Power Solutions, a
manufacturer of high-precision electrical connectivity components used in
electric vehicles, energy management, industrial, and mobility markets. This
acquisition is expected to help Eaton expand its portfolio of products and
In June 2021, GE-Prolec Transformers, Inc. signed an agreement
with SPX Corporation to acquire its SPX Transformer Solutions business for USD
645 million. This acquisition is expected to enhance GE-Prolec's position as a
key distribution and power transformer supplier, providing customers with a
wider range of products and an improved portfolio.
In February 2019, Siemens AG, a leading player in the
market, introduced its on-demand mobile resilience transformer leasing offer.
This offering allows utility suppliers and owners to lease its PRETACT Plug
& Play GSU Resilience Transformer for emergency response. This innovation
can provide asset owners with a more reliable and secure power supply by
leasing the critical equipment locally for quick installation, as the GSU
resilience transformer can be installed in a short time.
The industrial control transformer market has seen several
recent developments, primarily driven by advancements in technology and
increasing demand across various industries.
One significant development is the use of smart industrial
control transformers, which offer remote monitoring, predictive maintenance,
and advanced diagnostics capabilities. These transformers are equipped with
sensors that provide real-time data, enabling proactive maintenance and
preventing potential system failures. The growing adoption of smart industrial
control transformers is expected to boost the market's growth in the coming
Another development is the increasing focus on
energy-efficient transformers that help reduce energy consumption and lower
operational costs. These transformers are designed to provide stable and
efficient power supply, while minimizing energy losses during transmission.
Several manufacturers are investing in research and development to develop more
energy-efficient transformers that comply with industry regulations and
Moreover, the market is also witnessing significant demand
from the renewable energy sector. Industrial control transformers are crucial
components in wind and solar power generation systems, where they are used to
convert and control electrical energy for transmission and distribution. The
growing adoption of renewable energy sources is expected to drive the demand
for industrial control transformers in the coming years.
Furthermore, manufacturers are focusing on expanding their
product portfolios and developing customized solutions to meet specific
end-user requirements. This strategy is aimed at enhancing their market
presence and gaining a competitive edge in the industry. Several manufacturers are
also investing in mergers and acquisitions to strengthen their market position
and expand their customer base.
Overall, the industrial control transformer market is
expected to witness significant growth in the coming years, driven by the
increasing demand from various end-user industries and the development of
advanced and energy-efficient transformer technologies.
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