OpenPLC vs Studio 5000
Comprehensive comparison of two leading PLC programming platforms
OpenPLC
OpenPLC Project (Open Source)
Completely FREE - no costs ever
Studio 5000
Rockwell Automation / Allen-Bradley
Dominant in North American market - high job demand
Overall Winner
Studio 5000 leads with an overall score of 72/100
Studio 5000 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 | OpenPLC | Studio 5000 |
|---|---|---|
| Overall | 55 | 72✓ |
| Pricing | 100✓ | 45 |
| Ease of Use | 50 | 50 |
| Features | 63 | 77✓ |
| Industry Adoption | 18 | 88✓ |
| Community Support | 94 | 100✓ |
| Career Value | 23 | 76✓ |
Real-World Scenario Recommendations
See how OpenPLC and Studio 5000 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
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...
Studio 5000
Absolutely overkill for small machine builders. Studio 5000's subscription model ($2,000-$20,000 annually) is designed for large integrators and enterprises, not small OEMs. The CompactLogix hardware is robust but expensive. You're essentially renting software that could cost you $100,000+ over 5 years. The learning curve is steep (3-6 months), which delays your time-to-market significantly. Only ...
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.)
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...
Studio 5000
Mandatory standard for North American automotive Tier 1 suppliers, especially for GM, Ford, Chrysler, and their supply chains. Studio 5000 with ControlLogix and GuardLogix safety PLCs is what these OEMs specify in their automation standards documents. The subscription model ($2,000-$20,000 annually per seat) is expensive, but your customer expects it. For powertrain and final assembly lines in Nor...
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
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.
Studio 5000
Dominant in North American process industries, particularly oil and gas, petrochemical, and refining. Studio 5000 with ControlLogix and GuardLogix safety PLCs is the de facto standard for US refineries and chemical plants. The PlantPAx process automation system (built on ControlLogix) provides comprehensive DCS-like functionality using PLC architecture - cost-effective compared to traditional DCS ...
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 Studio 5000 ($$$). OpenPLC costs between $0 and $0, while Studio 5000 ranges from $2 000 to $20 000.
📚Learning Curve
Both OpenPLC and Studio 5000 have similar learning curves (rated 6/10). Expect 3-6 months to become proficient with either platform.
⚙️Features & Capabilities
OpenPLC offers 11 key features. Studio 5000 provides 11 key features with safety programming, motion control. Both platforms offer a comprehensive feature set for industrial automation.
🏭Industry Adoption
Studio 5000 has 80% market adoption compared to OpenPLC's 10%. Studio 5000 dominates in North America, Latin America, while OpenPLC is strongest in Global (primarily education and research). Studio 5000's higher adoption means more job opportunities and community resources.
🔌Hardware Compatibility
OpenPLC is designed specifically for Generic/Open Hardware hardware, while Studio 5000 works with Allen-Bradley, Rockwell Automation PLCs. Both are vendor-specific solutions optimized for their respective hardware ecosystems.
💼Career Prospects
Studio 5000 offers stronger career prospects with 80% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, Studio 5000 expertise is more in-demand.
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
Studio 5000 Overview
Key Strengths
- ✓Dominant in North American market - high job demand
- ✓Excellent integration with Rockwell ecosystem
- ✓Strong motion control capabilities
- ✓Good safety system programming tools
Limitations
- ✗Very expensive licensing model
- ✗Limited to Allen-Bradley/Rockwell hardware
- ✗Subscription model increases long-term costs
Best For
Recommendations
For Beginners
Both are suitable
For Professionals
Studio 5000
Budget-Constrained
OpenPLC
Enterprise Use
Studio 5000
Frequently Asked Questions
Which is better: OpenPLC or Studio 5000?
Studio 5000 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 OpenPLC and Studio 5000?
OpenPLC (free) is significantly more affordable than Studio 5000 ($$$). OpenPLC costs between $0 and $0, while Studio 5000 ranges from $2 000 to $20 000.
Which is easier to learn: OpenPLC or Studio 5000?
Both OpenPLC and Studio 5000 have similar learning curves (rated 6/10). Expect 3-6 months to become proficient with either platform.
Which has better career prospects?
Studio 5000 offers stronger career prospects with 80% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, Studio 5000 expertise is more in-demand.