Automation Studio vs OpenPLC
Comprehensive comparison of two leading PLC programming platforms
Automation Studio
B&R Industrial Automation (ABB Group)
Excellent for high-speed packaging machinery
OpenPLC
OpenPLC Project (Open Source)
Completely FREE - no costs ever
Overall Winner
Automation Studio leads with an overall score of 70/100
Automation Studio is the stronger overall choice with better community support. However, OpenPLC may be preferable if you prioritize pricing or if you're already committed to the OpenPLC Project (Open Source) ecosystem.
Score Breakdown
| Category | Automation Studio | OpenPLC |
|---|---|---|
| Overall | 70✓ | 55 |
| Pricing | 75 | 100✓ |
| Ease of Use | 50 | 50 |
| Features | 84✓ | 63 |
| Industry Adoption | 55✓ | 18 |
| Community Support | 91 | 94✓ |
| Career Value | 68✓ | 23 |
Real-World Scenario Recommendations
See how Automation Studio and OpenPLC perform in specific industry scenarios to help guide your decision.
Small Machine Builder
OEM building compact machines with 50-200 I/O points, typically for niche markets or specialized applications
Automation Studio
Excellent choice for small OEMs focused on packaging, food processing, or pharmaceutical machinery. B&R (now ABB) Automation Studio licensing ($1,000-$8,000) is reasonable, and the Mapp Technology framework dramatically accelerates development. These pre-built function blocks handle common packaging tasks (conveyor control, recipe management, batch processing) that would take weeks to program from...
OpenPLC
Interesting for proof-of-concept or extremely budget-constrained startups, but risky for commercial machines. The appeal is obvious: completely FREE, runs on Raspberry Pi ($35-$100 hardware cost), zero licensing restrictions. Perfect for: (1) Building your first prototype to secure investor funding, (2) Educational machines or demonstration units, (3) Very simple control tasks with forgiving indus...
Key Considerations:
- •Per-machine software licensing cost vs expected production volume
- •Time-to-market pressure - can you afford 6+ month learning curves?
- •Target customer geography and brand preferences
- •Hardware cost optimization - some platforms offer cheaper controllers
Automotive Tier 1 Supplier
Tier 1 automotive supplier providing systems and components directly to OEM vehicle manufacturers (VW, BMW, GM, Ford, Toyota, etc.)
Automation Studio
Strategic choice for Tier 1 suppliers specializing in specific automotive sectors where B&R excels: automotive paint shops (B&R has strong track record in paint atomizer control), electric vehicle battery assembly (precision handling and traceability), and automotive glass manufacturing. ABB's ownership of B&R (since 2017) has strengthened automotive credentials. The Automation Studio licensing ($...
OpenPLC
Not viable for automotive Tier 1 production equipment. Automotive OEMs have strict certification, safety, and vendor support requirements that OpenPLC cannot meet. Insurance, liability, and customer acceptance issues eliminate this option. Possibly acceptable for internal R&D labs, proof-of-concept demonstrations, or training junior engineers before expensive platform licenses. Otherwise, avoid fo...
Key Considerations:
- •Customer-specified platforms are non-negotiable - verify before any engineering investment
- •Long-term parts availability (15-20 years) is critical for automotive
- •Safety certifications (SIL 2/SIL 3) must be well-established and accepted
- •Customer's plant maintenance teams must be trained on your platform
Process Industry (Chemical, Oil & Gas, Pharma)
Continuous process control in chemical plants, refineries, pharmaceutical manufacturing, and other process industries requiring high reliability and regulatory compliance
Automation Studio
Limited process industry adoption despite B&R's capabilities. The Automation Studio platform is primarily oriented toward discrete manufacturing and packaging. While technically capable of process control, the ecosystem lacks deep integration with process instrumentation and safety systems common in chemical, oil and gas, or pharmaceutical applications. The market positioning doesn't emphasize pro...
OpenPLC
Completely unsuitable for process industries. The lack of safety certifications, redundancy, regulatory compliance documentation, and vendor support eliminates OpenPLC from consideration. Process industries cannot accept uncertified control systems due to safety, environmental, and regulatory requirements. Not viable even for non-critical applications in regulated environments.
Key Considerations:
- •Redundancy and high availability are mandatory for critical processes
- •Safety certifications (SIL 2/SIL 3) for emergency shutdown systems
- •Long-term vendor support (20-30 year plant lifecycles)
- •Integration with process instrumentation and field devices
💰Pricing Comparison
OpenPLC (free) is significantly more affordable than Automation Studio ($$). OpenPLC costs between $0 and $0, while Automation Studio ranges from $1 000 to $8 000.
📚Learning Curve
Both Automation Studio and OpenPLC have similar learning curves (rated 6/10). Expect 4-6 months to become proficient with either platform.
⚙️Features & Capabilities
Automation Studio offers 11 key features including safety programming, motion control, robotics integration. OpenPLC provides 11 key features. Both platforms offer a comprehensive feature set for industrial automation.
🏭Industry Adoption
Automation Studio has 45% market adoption compared to OpenPLC's 10%. Automation Studio dominates in Europe, North America, Asia-Pacific, while OpenPLC is strongest in Global (primarily education and research). Automation Studio's higher adoption means more job opportunities and community resources.
🔌Hardware Compatibility
Automation Studio is designed specifically for B&R Automation (ABB) hardware, while OpenPLC works with Generic/Open Hardware PLCs. Both are vendor-specific solutions optimized for their respective hardware ecosystems.
💼Career Prospects
Automation Studio offers stronger career prospects with 45% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, Automation Studio expertise is more in-demand.
Automation Studio Overview
Key Strengths
- ✓Excellent for high-speed packaging machinery
- ✓Strong motion control capabilities
- ✓Modern development environment
- ✓C/C++ programming option for complex logic
Limitations
- ✗Less common than Siemens/Rockwell (fewer jobs)
- ✗Smaller user community
- ✗Limited third-party resources
Best For
OpenPLC Overview
Key Strengths
- ✓Completely FREE - no costs ever
- ✓Open source - fully customizable
- ✓Runs on inexpensive hardware (Raspberry Pi)
- ✓Perfect for learning without financial investment
Limitations
- ✗Not suitable for commercial/industrial use
- ✗No official support (community only)
- ✗Limited features compared to commercial PLCs
Best For
Recommendations
For Beginners
Both are suitable
For Professionals
Automation Studio
Budget-Constrained
OpenPLC
Enterprise Use
Automation Studio
Frequently Asked Questions
Which is better: Automation Studio or OpenPLC?
Automation Studio is the stronger overall choice with better community support. However, OpenPLC may be preferable if you prioritize pricing or if you're already committed to the OpenPLC Project (Open Source) ecosystem.
What is the price difference between Automation Studio and OpenPLC?
OpenPLC (free) is significantly more affordable than Automation Studio ($$). OpenPLC costs between $0 and $0, while Automation Studio ranges from $1 000 to $8 000.
Which is easier to learn: Automation Studio or OpenPLC?
Both Automation Studio and OpenPLC have similar learning curves (rated 6/10). Expect 4-6 months to become proficient with either platform.
Which has better career prospects?
Automation Studio offers stronger career prospects with 45% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, Automation Studio expertise is more in-demand.