Allen Bradley vs. Omron PLCs: A Comprehensive Industrial Comparison
Programmable Logic Controllers (PLCs) are the cornerstone of modern industrial automation. Designed to handle complex control tasks with speed and precision, PLCs have replaced the outdated relay-contact systems that once dominated factories. These earlier systems were plagued with messy wiring, high maintenance, limited functionality, and poor scalability.
PLCs brought about a revolution in automation by enabling programmable storage and logic-based decision-making. They now serve as control centers for everything from robotic arms and conveyor belts to high-precision diagnostics and motion systems.
Among the many manufacturers in the PLC market, Allen Bradley (AB) and Omron are two standout players. This blog compares them across key performance, cost, and usability factors to help you choose the best PLC for your application.
📊 Market Share and Industry Popularity
Allen Bradley commands a dominant 42% share of the North American PLC market, compared to Omron’s modest 2–3%. AB’s reputation is especially strong in the United States, where it's considered the go-to brand for process automation.
According to a global survey of 50 automation companies in 2012 [source needed], AB ranked 5th globally, while Omron placed 11th. Recent data shows AB climbing to 2nd place, with Omron now in 5th, reflecting growing confidence in both brands.
💰 Cost Comparison: Budget vs. Total Investment
One of the most significant differences lies in pricing. Omron PLCs can cost up to 90% less than Allen Bradley for similar functionality, making them an excellent choice for smaller or cost-sensitive applications.
But the total cost of ownership (TCO) goes beyond initial hardware:
| Factor | Recommended Brand | Why |
|---|---|---|
| Training availability | Allen Bradley | Extensive global resources |
| Replacement parts | Omron | Faster and cheaper procurement |
| Software integration | Allen Bradley | Better compatibility with SCADA, HMI |
| Licensing & maintenance | Omron | Fewer fees |
| Failsafe features | Allen Bradley | Better fault detection & tolerance |
Note: Omron’s low cost can be offset by longer development time due to a steeper learning curve in its programming environment.
🔄 Application Focus: Machine vs. Process Control
Omron PLCs are machine-focused, typically requiring more units across an industrial plant.
Allen Bradley PLCs are process-oriented, capable of controlling large-scale operations with fewer units.
For high-end motion controls and direct logic integration, AB’s PLCs are ideal. The Allen Bradley Pico series can often match the functionality Omron provides, but with broader capabilities.
🧩 Hardware Variety and Flexibility
🔷 Allen Bradley (Rockwell Automation)
- ControlLogix – High-end, full-featured
- CompactLogix – Modular mid-tier
- SLC & MicroLogix – Cost-effective small systems
Key benefits include backward compatibility, safety features, and configuration flexibility in communication, memory, and environment-specific options.
🔶 Omron
- Models: CJ2M, CP2E, CP1H, CP1L, CS1D
- CJ2M supports up to 2,500 digital I/O
- Native Ethernet, serial, and CompoBus/S support
Omron’s systems integrate easily with multi-axis control, vision systems, and sensors—ideal for compact spaces and tight budgets.
⚙️ Programming: Simplicity vs. Learning Curve
Allen Bradley
- Software: RSLogix, Studio 5000
- Easy-to-learn for beginners
- Robust community and documentation
Omron
- Software: CX-Programmer
- Graphical programming with drag-and-drop function blocks
- Faster development for simpler applications
Function Blocks Tip: Omron's visual programming makes it easier for beginners to build logic without writing extensive code.
🌡️ Environmental Durability
Allen Bradley XT
- Operating range: -25°C to +70°C
- Meets G1–G3 pollution class standards
- Designed for oil, gas, steel, and maritime sectors
Omron
- Specialized for food, pharma, and chemical washdowns
- Sensor tech includes E2E and E2A for high resistance
- Ideal for dust, moisture, and vibration-heavy environments
👥 Technical Support and Customer Service
Allen Bradley
- World-class documentation
- 24/7 global support (often paid)
- Extensive tutorials and upgrade paths
Omron
- Multilingual (English, French, Spanish)
- Quick support: <3 minutes average wait
- Free troubleshooting during business hours
- Advanced services on request
🌍 Manufacturing Footprint
Omron has facilities in Shanghai, Kusatsu, Ayabe, and the Netherlands, with Shanghai being the largest.
Allen Bradley operates globally, including in Germany, UK, Switzerland, Japan, China, Korea, Canada, Mexico, and across the U.S.
✅ Conclusion: Which PLC Should You Choose?
| Use Case | Best Fit |
|---|---|
| Large-scale, process-oriented systems | Allen Bradley |
| Cost-sensitive machine automation | Omron |
| Harsh industrial environments | Both (depends on use case) |
| Extensive vendor support & integration | Allen Bradley |
| Quick deployment & low setup cost | Omron |