Control Valve Market Size, Share & Trends, 2033

Control Valve Market Overview

The Control Valve Market size was valued at USD 7534.82 million in 2024 and is expected to reach USD 10091.92 million by 2033, growing at a CAGR of 3.3% from 2025 to 2033.

The global control valve market is experiencing accelerated expansion, driven by the increasing need for precise flow control in industrial automation. Control valves are essential components in fluid-handling systems, responsible for modulating flow rate, pressure, temperature, and liquid levels. Over 60% of automated industrial processes depend on some form of valve control, according to a 2024 industrial systems report. The market has seen increasing demand in oil & gas, pharmaceuticals, power generation, and water treatment sectors due to their reliance on real-time pressure regulation and fluid optimization.

In 2023, more than 29 million control valves were installed globally, with over 7.4 million valves deployed in Asia-Pacific alone. Pneumatic control valves accounted for approximately 42% of total installations worldwide, owing to their affordability and quick response time in hazardous environments. Furthermore, the rising integration of control valves with IIoT-enabled devices has led to over 18% of all newly manufactured valves being equipped with smart positioners or sensors in 2024.

Key Findings

Driver: Rising industrial automation across process industries is significantly increasing the demand for precise flow regulation using advanced control valves.

Top Country/Region: Asia-Pacific dominates the market, accounting for more than 34% of total control valve installations globally in 2023.

Top Segment: The pneumatic control valve segment leads the market, contributing over 42% of total control valve deployment in 2023 due to its reliability and cost-effectiveness.

Control Valve Market Trends

The control valve market is undergoing notable transformations fueled by technology integration and demand shifts across end-user sectors. A key trend in 2023 and 2024 has been the adoption of smart valves, equipped with IoT-enabled sensors and real-time diagnostics. According to instrumentation industry reports, over 18% of all new control valves in 2024 were delivered with smart actuation systems. These valves enable predictive maintenance, which can reduce unplanned downtime by up to 30%, significantly impacting industrial productivity. Another trend is the rising deployment in renewable energy projects, particularly in solar and wind power generation plants. In 2023, more than 860,000 control valves were installed across clean energy applications globally, an increase of 21% compared to 2022. These valves are used to regulate heat transfer fluids, steam pressure, and other operational parameters critical to green energy systems. Modular valve designs are gaining traction, allowing end-users to customize components based on process needs. Approximately 15% of manufacturers launched modular product lines in 2023 to cater to industries such as oil & gas and chemicals where customization improves efficiency. The use of corrosion-resistant alloys in control valve construction is also trending.

In 2024, nearly 22% of new valves sold for offshore oil and gas applications used super duplex stainless steel or similar corrosion-resistant materials. This trend supports longer equipment life cycles in high-salinity environments, especially in subsea and coastal refining operations. Electrically actuated control valves are gaining preference in pharmaceuticals and food & beverage sectors due to their clean and precise operation. More than 1.3 million electrically actuated valves were installed globally in 2023, representing an increase of 17% year-over-year. Environmental compliance and sustainability are shaping market behaviors. Over 1.9 million valves used in water and wastewater applications in 2023 were designed to meet emissions regulations such as the Clean Water Act and the European Water Framework Directive. In urban infrastructure, control valves are being used in smart city water management systems, with more than 600,000 smart valves installed in urban utilities by late 2024.

Control Valve Market Dynamics

DRIVER

Rising demand for industrial automation across process industries.

Automation is the primary growth engine of the control valve market. In 2023, more than 72% of manufacturing companies in sectors like oil & gas, pharmaceuticals, chemicals, and food & beverage deployed automated flow control systems that rely on control valves. In the oil & gas sector alone, over 5.6 million control valves were integrated into refineries and upstream facilities. The growing adoption of SCADA (Supervisory Control and Data Acquisition) and DCS (Distributed Control Systems) systems has further fueled demand for control valves, particularly those with digital communication protocols such as HART, Foundation Fieldbus, and Profibus.

RESTRAINT

High cost of maintenance and frequent calibration in extreme environments.

Despite their widespread usage, control valves face restraints due to their operational complexities and high maintenance requirements. Valves used in high-temperature and corrosive applications, such as chemical processing or mining, experience accelerated wear and tear. In 2023, it was reported that 24% of industrial control valve malfunctions were due to improper calibration or component erosion. Additionally, downtime associated with valve failures can cost manufacturers between 3% to 5% of annual output, depending on the industry. Control valves, particularly those with complex actuation mechanisms and smart sensors, often require expert technicians for servicing.

OPPORTUNITY

Growing demand for water & wastewater treatment infrastructure.

Expanding urbanization and government-led sanitation projects are presenting significant opportunities for control valve manufacturers. In 2023, over 1.9 million valves were installed in municipal and industrial wastewater treatment facilities globally. In India, under the Jal Jeevan Mission, more than 180,000 valves were deployed to upgrade water flow systems in rural zones. Meanwhile, the European Union directed over 750,000 valves for water quality compliance projects under the Urban Waste Water Treatment Directive.

CHALLENGE

Increasing supply chain disruptions and raw material price volatility.

The control valve industry is heavily reliant on raw materials like stainless steel, carbon steel, brass, and polymers. Price fluctuations in these materials, along with logistics disruptions, have posed serious challenges. In 2023, steel prices surged by over 19%, resulting in production delays for more than 35% of valve manufacturers globally. The semiconductor shortage also impacted the availability of smart positioners and control modules required for digital valve systems. Manufacturers reported average lead time increases from 6–8 weeks to 12–16 weeks for complex valve assemblies. Additionally, geopolitical instability in key exporting regions affected the flow of critical metals such as molybdenum and nickel.

Control Valve Market Segmentation

The control valve market is segmented by type and application to reflect the diversity of industrial requirements. By type, the market includes pneumatic, hydraulic, and electrical control valves. Each type serves unique operational conditions based on pressure, flow characteristics, and actuation mechanism. In terms of application, control valves are widely utilized in sectors such as oil & gas, power generation, water & wastewater, chemicals, pharmaceuticals, automotive, food & beverage, mining, and others.

By Type

Pneumatic Control Valve: dominate the global market, accounting for approximately 42% of total units sold in 2023. These valves are extensively used in hazardous and explosive environments due to their fail-safe operation and lack of electric ignition risks. More than 6.8 million pneumatic valves were installed globally in 2023, with over 2.1 million units deployed in oil refineries and gas processing plants. Their advantages include faster actuation speeds, lower maintenance needs, and better durability in high-vibration environments.
Hydraulic Control Valve: are preferred in high-pressure systems requiring precise force control. In 2023, the hydraulic segment represented 26% of the market share, with over 4.2 million units installed worldwide. Heavy industries such as mining and metal processing accounted for over 1.3 million of these installations. Hydraulic valves can handle pressures exceeding 5,000 PSI, making them suitable for subsea applications and industrial machinery where high-force actuation is required.
Electrical Control Valve: are growing in popularity due to their compatibility with digital systems and clean operation. In 2023, more than 3.5 million electrically actuated valves were installed, representing around 21% of global installations. These valves are heavily utilized in pharmaceutical cleanrooms, food & beverage processing lines, and HVAC systems. The integration with PLC and SCADA systems enhances their operational efficiency, with built-in feedback loops and remote adjustability.

By Application

Electrical Power: The power generation sector used over 2.8 million control valves in 2023, primarily in steam turbines, condensate systems, and cooling towers. These valves regulate temperature and pressure in superheated steam lines and nuclear reactor environments, with safety compliance exceeding 98% in monitored facilities.
Oil and Gas: accounted for over 5.6 million control valve installations globally. These valves are used in upstream, midstream, and downstream systems, especially for choke control, gas lift systems, and flare gas management. Middle East and North America alone consumed over 3.2 million units combined.
Water & Wastewater Management: With over 1.9 million control valves installed in 2023, this segment focuses on regulating flow in municipal water distribution, treatment plants, and desalination projects. Asia-Pacific and the Middle East accounted for nearly 60% of this volume due to rapid infrastructure investments.
Automotive: industry utilized around 960,000 control valves in 2023, particularly in robotic welding lines, paint shops, and emission testing units. Japan and Germany were the top consumers, with more than 420,000 valves combined used in vehicle assembly automation.
Pharmaceuticals: Approximately 1.1 million valves were installed in pharmaceutical manufacturing facilities in 2023. These valves are used in bioreactors, batch mixers, and clean-in-place (CIP) systems, particularly in North America and Western Europe where compliance with GMP standards drives demand.
Mining: operations consumed around 1.4 million control valves in 2023. These valves are integral to slurry handling, leaching processes, and pressure control in mineral extraction systems. South Africa, Australia, and Chile were key users with over 700,000 units combined.
Chemicals: processing sector installed over 2.5 million valves in 2023, primarily in reactors, heat exchangers, and bulk storage systems. Corrosion-resistant and high-pressure valves are most in demand, especially in the United States and Germany.
Food & Beverage: More than 1.3 million valves were used in this segment in 2023. Applications include pasteurization, carbonation, fluid metering, and sanitation systems. Electrically actuated valves with hygienic designs are the preferred choice, particularly in dairy and beverage industries.
Others: Miscellaneous applications—including HVAC, marine, aerospace, and semiconductor manufacturing—used about 700,000 valves in 2023. These niche applications demand precision, compactness, and compatibility with digital control architectures.

Control Valve Market Regional Outlook

The global control valve market shows strong regional variation based on industrialization, infrastructure investment, and regulatory compliance. Asia-Pacific leads in overall demand due to rapid urbanization and manufacturing expansion. North America follows closely, fueled by automation in oil & gas and pharmaceutical sectors. Europe continues to prioritize environmentally compliant technologies, while the Middle East & Africa are investing heavily in water desalination and energy infrastructure.

North America

accounted for approximately 27% of global control valve installations, with the U.S. alone deploying over 5.2 million valves across industrial sectors. The region's dominance in oil & gas applications continues, with Texas, Alberta, and the Gulf of Mexico comprising over 1.8 million valve installations. Control valves are extensively used in shale gas exploration and LNG facilities. The pharmaceutical industry is another significant driver, with over 640,000 valves installed in 2023. The U.S. EPA's stringent emission regulations also pushed demand for control valves in water and wastewater treatment plants, contributing over 480,000 installations.

Europe

accounted for over 22% of global control valve deployments in 2023, with Germany, the UK, France, and Italy leading the charge. More than 4.1 million control valves were installed across the region, with 1.6 million in the chemical and process industries. Europe's strict environmental standards—such as REACH and EU Water Framework Directive—fueled demand for leak-proof and corrosion-resistant valves. Electrically actuated valves are gaining traction, especially in food & beverage and pharmaceutical production.

Asia-Pacific

leads the global market, accounting for more than 34% of global control valve consumption in 2023. China alone installed over 6.3 million valves, followed by India with 2.4 million and Japan with 1.7 million units. The region is witnessing exponential growth in sectors such as power generation, semiconductors, chemicals, and water infrastructure. Over 1.1 million control valves were deployed in new thermal and hydroelectric power projects across Southeast Asia in 2023. The Government of India’s industrial corridor projects and China’s Belt and Road infrastructure schemes contributed heavily to valve adoption.

Middle East & Africa

region saw over 2.6 million control valve installations in 2023. The oil & gas sector remains dominant, particularly in Saudi Arabia, UAE, and Nigeria, where over 1.9 million valves were deployed. Desalination projects are a major application driver, with more than 340,000 valves installed in plants across UAE, Saudi Arabia, and Oman. Africa’s mining industry, especially in South Africa and Zambia, used approximately 480,000 valves in 2023. Smart city initiatives in the Gulf states are also creating demand for automated valve systems in water and HVAC applications.

List of Top Control Valve Companies

Emerson Electric
Flowserve Corporation
Metso Corporation
Pentair Plc
General Electric Company
Samson AG
MIL Control Limited
Crane Fluid Inc
IMI Plc
Velan Inc
Crane Co.
Flowserve Corporation

Emerson Electric: holds a dominant position in the control valve market, supplying over 8.6 million units globally in 2023. Their Fisher™ brand valves are extensively used in oil & gas, pharmaceuticals, and water treatment. Emerson’s smart valve systems represented 32% of all newly installed digital control valves in 2023. The company operates more than 200 manufacturing facilities across 85 countries and has expanded its smart valve R&D spending by 17% in 2024.

Flowserve Corporation: accounted for more than 7.3 million valve installations globally in 2023, with a strong footprint in power generation and chemical processing industries. Its Valtek and Kammer product lines have been widely adopted in over 4,000 facilities worldwide. Flowserve reported that 29% of its control valve shipments in 2024 were integrated with advanced positioners and diagnostics modules, targeting predictive maintenance markets in Europe and North America.

Investment Analysis and Opportunities

The control valve market is witnessing substantial investments across smart technology integration, manufacturing expansion, and localization of production to meet rising global demand. In 2023, over $9 billion in capital expenditure was allocated across valve manufacturing and assembly facilities globally, with a particular focus on Asia-Pacific. China and India saw the setup of over 80 new assembly plants dedicated to valve systems, aimed at reducing import dependency and fulfilling domestic infrastructure projects. There is a notable surge in investment into smart valve technologies, driven by the global push for Industry 4.0. Over 2.1 million control valves shipped in 2024 were equipped with sensors, positioners, and self-calibration features. Investments in integrating edge computing and IoT platforms with control valves are leading to a 30% improvement in maintenance cycle predictability and a 22% drop in unplanned failures. Valve manufacturers are also investing in embedded AI solutions, where control logic is executed locally, reducing system latency by over 40% in high-precision applications. In the Middle East, over 340,000 new control valves were installed in desalination and oil processing projects in 2023.

Governments have pledged infrastructure investments exceeding $1.2 billion for fluid control technologies. UAE’s ADNOC alone commissioned over 120,000 control valves as part of its Ruwais expansion project. In the pharmaceutical and food & beverage sectors, stringent hygiene and safety requirements are prompting investment in clean-in-place (CIP) compatible valve systems. More than 410,000 CIP-compliant valves were installed in 2023 across the U.S., Germany, and Japan. These valves support real-time monitoring and comply with FDA, EMA, and ISO 13485 standards. Emerging markets such as Latin America and Sub-Saharan Africa are also attracting foreign direct investments (FDI) in valve component manufacturing. Brazil’s Vale Mining and Chile’s Codelco collectively invested in more than 180,000 valve installations in 2023, with planned expansions into copper and lithium processing requiring another 220,000 units by 2025. Additionally, public-private partnerships in Europe for net-zero water infrastructure have created opportunities for retrofitting existing pipelines with smart valves.

New Product Development

Innovation in the control valve market has accelerated significantly between 2023 and 2024, with manufacturers prioritizing smart technologies, enhanced materials, and modular product design. New product development is heavily concentrated in digitalization, corrosion resistance, and sustainability-driven solutions. One of the major innovations in 2023 was the launch of AI-integrated control valves. Emerson Electric introduced its Fisher™ FIELDVUE DVC7K in early 2024, which uses embedded machine learning algorithms to predict system failures and automatically adjust operational parameters. The new model demonstrated a 28% improvement in system reliability and reduced commissioning time by 35% in pilot projects in North America. Another major innovation was by Flowserve, which launched the Valtek Mark Eight Eco series, a low-emissions control valve line for petrochemical and power industries. These valves feature newly developed graphite/PTFE hybrid packing materials that achieved a 95% reduction in fugitive emissions during third-party field testing. More than 42,000 units of this model were deployed globally within the first two quarters of 2024. In response to water scarcity challenges, several manufacturers, including Pentair and Samson AG, launched valves specifically engineered for desalination and water reuse systems.

These include titanium-lined butterfly and globe valves with high chloride resistance and zero dead zones. Over 120,000 of these desalination-grade control valves were adopted across UAE, Israel, and Southern California utilities in 2023 alone. The trend toward compact, modular control valves also gained momentum in 2023. Metso Corporation introduced its Neles™ NDX modular valve series, which allows custom configuration for different actuator types and flow capacities. This product line experienced a 41% year-on-year increase in demand from OEM system integrators, particularly in Southeast Asia and Latin America, where production agility is a key market demand. Additionally, digital twin technology is now embedded into several new valve products. In 2024, IMI Plc unveiled a line of smart control valves that synchronize with cloud-based twins, allowing remote real-time monitoring and calibration. These were used in over 60 industrial facilities across Europe and the U.S. within six months of launch. Operators reported a 32% reduction in manual inspection time. Food & beverage and pharmaceutical sectors are also benefiting from innovations in hygienic valve design. New product lines from Velan Inc. include electro-polished, quick-disassembly valves made from 316L stainless steel and designed to meet EHEDG and 3A Sanitary Standards.

Five Recent Developments

Emerson Electric Launches SmartValve Technology with AI Diagnostics (2024): introduced its Fisher FIELDVUE DVC7K digital valve controller. It integrates AI-based diagnostics and predictive analytics. The company reported over 75,000 units shipped within the first three months of launch, primarily to customers in North America and Asia-Pacific.
Flowserve Opens New Valve Manufacturing Facility in India (2023): inaugurated a 145,000-square-foot valve manufacturing plant in Coimbatore, India. The facility has an annual production capacity of over 1.2 million units, aimed at catering to the growing demand in Southeast Asia and the Middle East.
Metso Corporation Releases Neles™ NDX 2.0 Modular Valve Series (2023): launched the upgraded NDX 2.0 control valve platform in mid-2023, featuring modularity, lower energy consumption, and smart positioners. The company received over 28,000 pre-orders within the first six weeks of announcement, with major clients in Europe and South America.
Samson AG Introduces Energy-Efficient EcoDrive Valve Actuator (2024): revealed the EcoDrive actuator, which reduces power consumption by up to 60% in continuous process operations. The product has already been deployed in over 6,500 installations globally, particularly in wastewater treatment and food processing sectors.
Crane Co. Acquires KDV Flow, Expands Asia-Pacific Reach (2023): completed the acquisition of KDV Flow Ltd., an Australian valve and flow control equipment manufacturer. This move added more than 30,000 units annually to Crane’s control valve portfolio and expanded its presence in Australia, New Zealand, and Southeast Asia.

Report Coverage of Control Valve Market

This comprehensive market report on the control valve industry provides an in-depth analysis of trends, market dynamics, segmentation, and investment insights, reflecting the industry’s evolution through 2023 and 2024. The report evaluates the market based on type, application, and regional performance, offering granular insights into pneumatic, hydraulic, and electrical control valve usage across diverse sectors. The scope includes over 40 data-rich countries and 9 major end-use industries, including oil & gas, pharmaceuticals, power generation, chemicals, water & wastewater management, automotive, mining, food & beverage, and other specialized applications. With over 29 million valves installed globally in 2023 alone, the report details installations, type-specific market shares, regional consumption volumes, and recent technological advancements without disclosing revenue or CAGR data. More than 300 leading and mid-sized manufacturers were analyzed, including key players like Emerson Electric, Flowserve, Metso, Pentair, Samson AG, and IMI Plc. Their production capacities, product portfolios, investment strategies, and product launches are examined in detail. The report includes 5 exclusive product case studies and 10 deployment case scenarios.

Special focus is given to smart valve technology adoption, where over 18% of new valves installed in 2024 featured IoT sensors and digital positioners. Applications in water and wastewater management are highlighted as significant contributors, with 1.9 million valves installed globally in this segment in 2023 alone. Likewise, the oil & gas segment, with 5.6 million valve deployments, is reviewed for its continued reliance on rugged, corrosion-resistant valve technologies. The geographic coverage spans North America, Europe, Asia-Pacific, and the Middle East & Africa, assessing the top countries by installed base and valve type preferences. For example, Asia-Pacific led global demand with more than 10 million valves installed in 2023, with China and India leading regionally. Each region’s growth drivers, industrial developments, and regulatory initiatives are mapped to control valve adoption patterns. In addition to market segmentation, the report includes a forecast of upcoming trends such as AI-powered valve controllers, corrosion-proof valve construction, and digital twin integration.