Best Process Controllers of 2025

Brian Howie Avatar
Brian Howie
Last Updated: Jan 2, 2025

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Process controllers are essential tools for maintaining optimal performance and efficiency in industrial processes. These devices are designed to monitor and regulate various parameters such as temperature, pressure, flow rate, and level. They provide real-time data and control signals to ensure that the process operates within specified limits and meets the desired quality standards. Process controllers come in different types and configurations, including single-loop, multi-loop, programmable, and digital models. They are widely used in various industries such as manufacturing, energy, chemical, and food processing. With advanced features such as remote monitoring and data logging, process controllers have become indispensable tools for modern industrial automation.

At a Glance: Our Top Picks

Hilitand 5 Axis CNC Motion Controller Cover#TOP 1
Hilitand 5 Axis CNC Motion Controller
ftb score rating icon9.8
Precision Digital PD6000-6R7 Controller Cover#TOP 2
Precision Digital PD6000-6R7 Controller
ftb score rating icon9.7
NOVUS N2000 USB Process Controller Cover#TOP 3
NOVUS N2000 USB Process Controller
ftb score rating icon9.5

Top 10 Process Controllers

#TOP 1

Hilitand 5 Axis CNC Motion Controller

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Hilitand 5 Axis CNC Motion Controller Cover
CNC Motion Controller, 5 Axis Offline Motion Controller Replace 500KHz USB Motion Controller
ftb score rating icon9.8
FTB Score

The Hilitand CNC Motion Controller offers a range of features designed to enhance your machining experience. With customizable control parameters, you can optimize the processing for better results tailored to your projects. It also supports various manual functions, making it easy for you to define operations that suit your needs. The manual operation capability allows you to perform tasks like jogging and returning to program zero effortlessly. Additionally, the program management feature enables you to create, modify, and save programs, ensuring that you can manage your workflow efficiently.

What We Like
Customizable control parameters
User-friendly manual functions
Easy manual operations
Efficient program management
#TOP 2

Precision Digital PD6000-6R7 Controller

PRECISION DIGITAL
PD6000-6R7
Precision Digital PD6000-6R7 Controller Cover
Precision Digital PD6000-6R7 ProVu Dual-Line Process Controller with 4 Realys + 4-20mA
ftb score rating icon9.7
FTB Score

The Precision Digital Process Controller is an advanced device designed for precise monitoring and control of processes. Its compact 1/8 DIN panel mount enclosure with a NEMA 4X front ensures durability and protection against harsh environments. You will appreciate the dual-line display featuring 0.6" high red LED digits, which makes reading measurements straightforward. The controller supports various inputs, including 4-20 mA and ±10 VDC, allowing you to customize it for your specific needs. Additionally, it provides transmitter power, making it convenient for powering your devices directly.

What We Like
Durable NEMA 4X enclosure
Clear dual-line LED display
Flexible input options
Transmitter power capability
#TOP 3

NOVUS N2000 USB Process Controller

8200200130
NOVUS N2000 USB Process Controller Cover
NOVUS 8200200130 4 RELAYS, N2000 USB, Process Controller, 1/8" DIN (48 X 96MM)
ftb score rating icon9.5
FTB Score

The NOVUS Process Controller is a compact 1/8" DIN device designed to enhance your temperature and process control needs. With four relays, it allows you to manage multiple processes simultaneously, giving you greater flexibility in your operations. The N2000 USB feature ensures easy connectivity and data transfer, making it convenient for you to monitor and adjust settings without hassle. Whether you are in industrial settings or other applications, this controller simplifies your workflow and ensures precise control over your processes.

What We Like
Compact size
Four relay outputs
USB connectivity
Temperature control
#TOP 4

Rotork SM-1630-0196 Motor

Rotork Process Controls
SM-1630-0196
Rotork SM-1630-0196 Motor Cover
Rotork Process Controls SM-1630-0196 Motor SM16300196
ftb score rating icon9.5
FTB Score

The Rotork Motor SM-1630 is designed for efficient performance in process control applications. With a current rating of 0.9 amps, this motor provides reliable power, ensuring consistent operation. It operates at both 50 and 60 hertz, making it versatile for different environments. The single-pole design contributes to its simplicity and ease of use. Operating at 120 volts, it delivers adequate energy while being compatible with standard electrical systems. This combination of features makes the Rotork Motor SM-1630 a dependable choice for your process control needs.

What We Like
Efficient power consumption
Versatile frequency options
Simple single-pole design
Standard voltage compatibility
#TOP 5

Red Lion DLC Dual Loop Controller

DLC0
Basic Unit
Red Lion DLC Dual Loop Controller Cover
Red Lion DLC Dual Loop Process Controller, 24 VAC or 18-36 VDC, 50/60 Hz
ftb score rating icon9.4
FTB Score

The Red Lion Dual Loop offers an efficient solution for multi-zone process control with its two independent PID control loops. This feature allows you to manage complex processes seamlessly, reducing overshoot for more accurate temperature and process control. You can easily configure the controller using Windows software, making setup straightforward. Additionally, it supports various input signals, enhancing its versatility in different applications. The RS485 Modbus protocol enables remote operations, giving you flexibility in managing your system from a distance.

What We Like
Two independent PID control loops
Windows configuration software
Supports multiple input types
Remote operation capability
#TOP 6

Trane UCP MOD01802 Control Module

MOD01802T
Trane UCP MOD01802 Control Module Cover
Trane Module; UNITARY Control Processor OTP - MOD01802 / MOD-1802
ftb score rating icon9.3
FTB Score

The Trane UCP Control Module is an essential component for managing your HVAC system. As an OEM unit, it ensures compatibility and reliability with American Standard and Trane systems. This module features a circuit board designed to optimize the performance of your unit, allowing you to maintain a comfortable environment efficiently. With multiple model compatibilities, it provides flexibility for various installations, making it a convenient choice for your needs. Additionally, its robust design ensures long-lasting service, giving you peace of mind about your HVAC system's operation.

What We Like
OEM compatibility
Optimizes HVAC performance
Flexible installation options
Durable design
#TOP 7

Powers Process Controls 512-D-1-0-I Controller

Generic
512-D-1-0-I
Powers Process Controls 512-D-1-0-I Controller Cover
Powers Process Controls 512-D-1-0-I Digital Controller
ftb score rating icon9.2
FTB Score

The Powers 512-D Controller is a reliable digital device perfect for managing various processes. Its used condition ensures that you get a functional product at a potentially lower price. This controller is categorized under process controllers, making it suitable for settings where monitoring and control of processes are essential. With its generic brand, it offers versatility and compatibility across different systems, allowing you to streamline operations effectively. This product can bring convenience to your workflow by providing accurate control and monitoring capabilities.

What We Like
Used condition, functional
Category: Process Controllers
Versatile and compatible
Streamlines operations
#TOP 8

Honeywell UDC3200 Controller Display

51452845-501
Honeywell UDC3200 Controller Display Cover
Honeywell 51452845-501 UDC3200 Controller Display
ftb score rating icon9.0
FTB Score

The Honeywell 51452845-501 UDC3200 Controller Display is a process controller with a UDC3500 Display/Keyboard.

What We Like
Easy-to-use display and keyboard interface.
Suitable for process control applications.
#TOP 9

Calt DY220 Load Cell Controller Indicator

CALT
DY220
Calt DY220 Load Cell Controller Indicator Cover
DY220 Load Cell Controller Indicator Batching Display Instruments Transmitter 2 relays Out(General Mode)
ftb score rating icon9.0
FTB Score

The Calt DY220 Controller is a versatile and efficient process controller designed for a wide range of applications. With a sampling rate of up to 80 times per second, this controller ensures accurate and real-time measurements. The General Mode feature allows for easy operation and customization to suit specific needs. The push pull force indicator provides precise force measurement, making it ideal for applications that require accurate force monitoring. The input voltage range of 100-230Vac ensures compatibility with various power sources. Additionally, the DY220 Controller features 2 relay outputs, offering flexibility for controlling external devices. With its advanced features and reliable performance, the Calt DY220 Controller is an excellent choice for process control applications.

What We Like
High sampling rate
General Mode for easy operation
Precise force measurement
#TOP 10

Honeywell L404F1102 Pressuretrol Controller

L404F1102
Honeywell L404F1102 Pressuretrol Controller Cover
Honeywell, Inc. L404F1102 L404A,B,C,D,F Pressuretrol Controllers
ftb score rating icon9.0
FTB Score

The Honeywell Pressuretrol Controller is designed to effectively manage process control applications. As a reliable controller, it helps you maintain optimal pressure levels, ensuring your systems operate efficiently. This model is part of Honeywell's trusted lineup, providing you with peace of mind in your operations. With its user-friendly design, you can easily monitor and adjust settings to suit your specific needs, enhancing overall productivity. Whether you are in industrial or commercial settings, this controller can streamline your processes and improve performance.

What We Like
Reliable pressure management
User-friendly design
Enhances operational efficiency
Trusted brand quality
Buying Guide Image

Frequently Asked Questions (FAQs)

1. What does a process controller do?

A process controller maintains the output of process variables, such as temperature, pressure, flow, or level, within a pre-set range. It uses feedback from sensors to detect any deviation from the desired setpoint and automatically adjusts the output to bring the parameters back within the desired range.

2. What are types of process controllers?

There are three main types of process control: open-loop, closed-loop, and feedback control. Process control strategies include proportional control, integral control, derivative control, PID control, cascade control, feedforward control, and ratio control.

3. What is an example of a process controller?

A common example of a process controller is a thermostat in a room. It consists of a temperature sensor, a heating element, and a cooling element. As the temperature fluctuates, the thermostat turns on either the heating or cooling system to maintain the room at a specific temperature.

4. What are the two commonly used process controllers?

The two commonly used process control systems are single input – single output (SISO) and multiple-input – multiple-output (MIMO). SISO is a simple control system that measures one process parameter, such as temperature, and converts it into an electrical signal for control purposes.

5. What are the three basic types of controllers?

The three basic types of controllers are on-off, proportional, and PID. The choice of controller depends on the specific system being controlled and the desired level of control over the process.

6. What are the three types of PID controllers?

PID controllers can be classified into three types: ON/OFF, proportional, and standard type controllers. The selection of the controller type depends on the control system and the desired regulation method.

Editor's Notes

During our process controller research, we found 24 process controller products and shortlisted 10 quality products. We collected and analyzed 1,187 customer reviews through our big data system to write the process controllers list. We found that most customers choose process controllers with an average price of $310.65.

The process controllers are available for purchase. We have researched hundreds of brands and picked the top brands of process controllers, including Hilitand, PRECISION DIGITAL, NOVUS, Rotork Process Controls, Red Lion. The seller of top 1 product has received honest feedback from 532 consumers with an average rating of 4.7.

Written by
Brian Howie Avatar

Brian Howie is a content writer and senior industrial designer. After graduation from Westminster College, he has been engaged in product design and manufacturing for 18 years. Brian Howie has always found great pleasure in designing industrial products and sharing his ideas and experience online.