OpenPLC vs TIA Portal
Comprehensive comparison of two leading PLC programming platforms
OpenPLC
OpenPLC Project (Open Source)
Completely FREE - no costs ever
TIA Portal
Siemens
Industry-leading integration with Siemens hardware
Overall Winner
TIA Portal leads with an overall score of 77/100
TIA Portal 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 | TIA Portal |
|---|---|---|
| Overall | 55 | 77✓ |
| Pricing | 100✓ | 50 |
| Ease of Use | 50 | 50 |
| Features | 63 | 79✓ |
| Industry Adoption | 18 | 95✓ |
| Community Support | 94 | 100✓ |
| Career Value | 23 | 85✓ |
Real-World Scenario Recommendations
See how OpenPLC and TIA Portal 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...
TIA Portal
Challenging choice for small OEMs. While TIA Portal offers exceptional capabilities, the licensing cost ($1,500-$15,000) can consume 10-30% of your entire automation budget on a single machine. The S7-1200 hardware is excellent and compact, but you're paying premium prices for enterprise features you may never use. Consider TIA Portal only if your end customers specifically require Siemens (common...
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...
TIA Portal
Often mandatory for European automotive OEMs, particularly German manufacturers (VW, BMW, Mercedes, Audi, Porsche). These companies explicitly specify Siemens in their supplier requirements documents - you have no choice. TIA Portal with S7-1500 Safety PLCs is the standard for assembly lines, body shops, and paint shops. The cost ($1,500-$15,000 per license, multiplied by 10-50 engineers) is signi...
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.
TIA Portal
Strong choice for process industries, particularly in Europe and pharmaceuticals. TIA Portal with S7-1500/S7-400 Redundancy (H-Systems) provides the high availability needed for critical processes. The hot-standby redundancy ensures control continuity during PLC failures - essential for processes that can't be interrupted (chemical reactions, pharmaceutical batch processes). The safety PLC capabil...
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 TIA Portal ($$$). OpenPLC costs between $0 and $0, while TIA Portal ranges from $1 500 to $15 000.
📚Learning Curve
Both OpenPLC and TIA Portal have similar learning curves (rated 6/10). Expect 3-6 months to become proficient with either platform.
⚙️Features & Capabilities
OpenPLC offers 11 key features. TIA Portal provides 11 key features with safety programming, motion control. Both platforms offer a comprehensive feature set for industrial automation.
🏭Industry Adoption
TIA Portal has 85% market adoption compared to OpenPLC's 10%. TIA Portal dominates in Europe, Asia-Pacific, Middle East, while OpenPLC is strongest in Global (primarily education and research). TIA Portal's higher adoption means more job opportunities and community resources.
🔌Hardware Compatibility
OpenPLC is designed specifically for Generic/Open Hardware hardware, while TIA Portal works with Siemens PLCs. Both are vendor-specific solutions optimized for their respective hardware ecosystems.
💼Career Prospects
TIA Portal offers stronger career prospects with 85% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, TIA Portal 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
TIA Portal Overview
Key Strengths
- ✓Industry-leading integration with Siemens hardware
- ✓Comprehensive all-in-one solution
- ✓Excellent documentation and training materials
- ✓Strong simulation capabilities
Limitations
- ✗Expensive licensing costs
- ✗Steep learning curve for beginners
- ✗Resource-intensive software (requires powerful PC)
Best For
Recommendations
For Beginners
Both are suitable
For Professionals
TIA Portal
Budget-Constrained
OpenPLC
Enterprise Use
TIA Portal
Frequently Asked Questions
Which is better: OpenPLC or TIA Portal?
TIA Portal 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 TIA Portal?
OpenPLC (free) is significantly more affordable than TIA Portal ($$$). OpenPLC costs between $0 and $0, while TIA Portal ranges from $1 500 to $15 000.
Which is easier to learn: OpenPLC or TIA Portal?
Both OpenPLC and TIA Portal have similar learning curves (rated 6/10). Expect 3-6 months to become proficient with either platform.
Which has better career prospects?
TIA Portal offers stronger career prospects with 85% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, TIA Portal expertise is more in-demand.