Flow Sensors Market Size and Share

Flow Sensors Market Analysis by Mordor Intelligence
The flow sensors market is currently valued at USD 9.11 billion and is projected to reach USD 12 billion by 2030, advancing at a 5.68% CAGR. Growth rests on rising digitalization across process industries, mandatory leak-detection rules in cross-border pipelines, and large-scale desalination investments that demand accurate, real-time measurement. Ultrasonic innovation, clamp-on retrofits, and IIoT connectivity shorten installation times, improve uptime, and help operators comply with evolving custody-transfer and environmental standards. At the same time, semiconductor shortages and high capital requirements for large-diameter Coriolis meters constrain the pace of adoption, nudging suppliers to redesign products around more readily available chipsets.
North America commands the largest revenue share because of strict pipeline safety mandates and aggressive smart-water rollouts, while Asia-Pacific records the fastest growth on the back of multi-billion-dollar manufacturing upgrades in China and India. Water and wastewater utilities represent the fastest-expanding end-user group as utilities prioritize non-revenue water reduction and asset reliability. Competition is intensifying: incumbents acquire niche ultrasonic specialists, launch IIoT service layers, and forge alliances to secure share in a market where data-as-a-service and miniaturized MEMS designs redefine value delivery.
Key Report Takeaways
- By type, liquid applications held 58.2% of the flow sensors market share in 2024, while gas applications trail; liquid flow measurement is forecast to expand at a 6.88% CAGR through 2030.
- By technology, differential-pressure sensors led with 31.03% revenue share in 2024, whereas ultrasonic sensors post the highest 7.11% CAGR through 2030.
- By installation type, inline meters accounted for 48.4% of revenue in 2024; clamp-on solutions are poised for the fastest 7.26% CAGR thanks to retrofit demand.
- By end-user industry, chemical & petrochemical processes captured 30.22% share in 2024, while water & wastewater applications will grow the quickest at 7.24% CAGR.
- By geography, North America dominated with 34.3% share in 2024, whereas Asia-Pacific is projected to be the fastest-growing region at a 6.32% CAGR.
Global Flow Sensors Market Trends and Insights
Drivers Impact Analysis
Driver | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
---|---|---|---|
Increasing adoption of smart and IIoT-enabled flow metering solutions | +1.2% | Global (Asia-Pacific leads) | Medium term (2-4 years) |
Surging demand for non-invasive clamp-on ultrasonic meters in retrofit projects | +0.9% | North America and EU; expanding to Asia-Pacific | Short term (≤ 2 years) |
Mandatory leak-detection regulations in cross-border oil and gas pipelines | +0.8% | Global; focus on North America | Long term (≥ 4 years) |
Rapid expansion of desalination and reuse plants in water-stressed economies | +0.7% | Middle East and North Africa; spillover to Asia-Pacific | Medium term (2-4 years) |
Miniaturized MEMS flow sensors for single-use bioprocessing equipment | +0.4% | North America and EU biotech hubs | Long term (≥ 4 years) |
Data-as-a-service business models creating recurring revenue | +0.3% | Global; early adoption in developed markets | Long term (≥ 4 years) |
Source: Mordor Intelligence
Increasing adoption of smart and IIoT-enabled flow metering solutions
Edge-ready sensors from suppliers such as KROHNE merge valve actuation with embedded flow, pressure, and temperature measurement, letting operators shift from reactive checks to predictive upkeep. Facilities that fitted IIoT-enabled sensors cut unplanned downtime by up to 30% because anomalies surfaced early. Local data processing lowers network load and empowers real-time safety actions. However, recent discoveries of remote-execution flaws in ABB TotalFlow computers spotlight cyber risks and underscore the need for hardened security frameworks.
Surging demand for non-invasive clamp-on ultrasonic meters in retrofit projects
Clamp-on units avoid pipe cutting and finish installation in roughly 30 minutes, a sharp contrast to multi-day inline retrofits[1]Badger Meter, “Clamp-On Ultrasonic Meter Installation Guide,” badgermeter.com. Power plants and chemical sites now favor the technology to refresh legacy lines without halts. Emerson’s FLUXUS series handles –200 °C to +630 °C, proving suitability in cryogenic and high-temperature duties. Automated meter verification permits on-site health checks, trimming maintenance hours and further boosting total asset utilization.
Mandatory leak-detection regulations in cross-border oil and gas pipelines
PHMSA’s updated rules oblige operators to install advanced detection programs and run frequent surveys, unlocking an estimated USD 341–1,440 million in annual benefits from safer operations. Continuous, real-time monitoring is now a compliance baseline, raising demand for highly accurate sensors that transmit data without latency. Harmonized U.S.-Canada standards simplify supplier certification while broadening total addressable opportunity. Technologies that combine leak sensing with methane-emissions tracking gain preference because of parallel climate targets.
Rapid expansion of desalination and reuse plants in water-stressed economies
Additional global desalination capacity will climb from 45 million to 61 million m³ per day by 2027, pushing orders for flow sensors that resist high salinity and pressure. The USD 1.9 billion Barka 5 facility in Oman and Dubai’s Hassyan plant both rely on electromagnetic and ultrasonic meters to maintain efficiency in reverse-osmosis processes. As renewables power a growing share of desalination, sensors must deliver stability under fluctuating energy inputs, favoring designs with wide turndown ratios and firmware-based signal compensation.
Restraint Impact Analysis
Restraint | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
---|---|---|---|
High CapEx for Coriolis meters in large-diameter custody-transfer lines | –0.8% | Global; oil and gas focus | Medium term (2-4 years) |
Scarcity of skilled calibration labs in emerging countries | –0.5% | Asia-Pacific, Africa, Latin America | Long term (≥ 4 years) |
Cyber-security vulnerabilities in wireless flow-meter networks | –0.4% | Global critical infrastructure | Short term (≤ 2 years) |
Supply-chain volatility for critical semiconductor chips | –0.6% | Global, Asia-Pacific manufacturing hubs | Medium term (2-4 years) |
Source: Mordor Intelligence
High CapEx for Coriolis meters in large-diameter custody-transfer lines
Each large-bore Coriolis installation can exceed USD 100,000, straining project budgets. Operators weigh the premium against alternative ultrasonic or differential-pressure options that cost less but deliver lower accuracy. Leasing models and outcome-based contracts offer relief, yet many custody-transfer codes enforce Coriolis-level precision, sustaining demand despite cost hurdles.
Supply-chain volatility for critical semiconductor chips
Lead times topping 40 weeks disrupt production of smart flow sensors. Contract manufacturers in Greater China dominate advanced microcontroller output, exposing OEMs to geopolitical shocks. Sensirion trimmed lead times by redesigning boards around multi-source chips, illustrating how component standardization mitigates risk. Persistent shortages push suppliers to balance feature sets against availability, occasionally delaying launches of next-generation wireless or AI-ready models.
Segment Analysis
By Type – Liquid applications drive market expansion
Liquid measurement held 58.2% of the flow sensors market in 2024 and is projected to grow at a 6.88% CAGR. Utility-scale smart-water projects boost demand, with Moulton Niguel Water District’s 55,000-meter rollout saving 500 million gallons annually mnwd.com. Electromagnetic variants remain dominant for conductive fluids, while ultrasonic sensors gain share in low-conductivity or slurry settings. On the gas side, pipeline monitoring and industrial combustion control sustain steady revenue, but lower growth keeps its contribution below the liquid segment.
Smart city mandates accelerate liquid adoption by compelling utilities to lower non-revenue water. Cary, North Carolina’s USD 18 million AMI platform eliminated 71,000 truck miles each year, demonstrating service cost reductions and emissions cuts[2]Water Online, “Cary Upgrades to AMI to Save Operational Costs,” wateronline.com. Chemical processors and breweries also propel liquid installations, particularly where sanitary standards or aggressive media require fully welded stainless-steel flow paths.
By Technology – Ultrasonic innovation reshapes the landscape
Differential-pressure devices still represent the largest revenue block at 31.03%, anchored by decades of installed base and favorable life-cycle economics. Yet ultrasonic sensors deliver the fastest 7.11% CAGR because clamp-on form factors reduce downtime, and advanced signal algorithms trim measurement error to 1%. The flow sensors market size tied to ultrasonic devices is positioned for double-digit gains in retrofit heavy industries through 2030.
Coriolis meters maintain premium status for multi-parameter measurement where density and mass flow are critical, while vortex and thermal variants address steam lines and low-flow gas applications. Magnetic sensors stay popular in water utilities and pulp plants due to zero pressure drop and corrosion-resistant liners. Integration of self-verification firmware across most technologies boosts operator confidence and lowers recalibration spend.
By Installation Type – Clamp-on technology transforms retrofits
Inline systems accounted for 48.4% revenue in 2024, favored in new plants that embed meters during construction. However, clamp-on deployments are set to chart the highest 7.26% CAGR as brownfield sites sidestep production outages. The flow sensors market size linked to clamp-on solutions grows steadily as operators in oil, chemical, and hydropower settings prioritize minimal intrusion and faster regulatory sign-off.
Insertion-type probes fill a cost-sensitive niche for large-diameter pipes across district energy and municipal water. Although they introduce slight pressure drop, their economic advantage in very large bores sustains adoption particularly in emerging regions with tight capital budgets.

Note: Segment shares of all individual segments available upon report purchase
By End-user Industry – Water sector leads the digital shift
Chemical and petrochemical plants captured 30.22% of 2024 revenue on the back of safety rules mandating continuous flow checks for hazardous media. Yet the water and wastewater segment expands the fastest at 7.24% CAGR, fueled by regulatory directives that push utilities to curb losses and expand reuse. For instance, the American Water Works Association projects USD 1 trillion in pipe and meter upgrades, creating a sizable pipeline for sensor suppliers.
Pharmaceutical bioprocessing now adopts single-use MEMS sensors compatible with sterilization cycles. Power generation seeks higher accuracy to boost turbine efficiencies, while food and beverage plants lean on sanitary-design Coriolis and magnetic meters for CIP-ready operations.
Geography Analysis
North America controlled 34.3% of 2024 revenue thanks to PHMSA’s stringent leak-detection rules and significant smart-water grants. Austin Water’s USD 80.2 million meter modernization illustrates how infrastructure packages unlock multi-year sensor procurement[3]Government Technology, “Austin Water Approves USD 80 Million Smart Meter Rollout,” govtech.com. Federal incentives for methane-reduction technologies further raise spending by pipeline operators on high-precision sensors that feed automated alert systems.
Asia-Pacific records a 6.32% CAGR, the highest worldwide. Annual investments topping USD 1.7 billion in Chinese and Indian automation projects spur demand across automotive paint shops, chemical complexes, and electronics fabs. Local vendors challenge global incumbents with price-competitive inline magmeters and simple vortex models, forcing multinationals to sharpen local support and value-added analytics. Southeast Asia benefits from electronics and battery gigafactory inflows that require tight flow control in ultrapure water and chemical lines.
Europe posts stable, regulation-led demand as the revised wastewater directive tightens discharge norms, compelling municipalities to fit continuous monitoring. Middle East and Africa see double-digit spending on desalination megaprojects such as Oman’s Barka 5 that depend on corrosion-resistant flow solutions. In South America, sensor uptake is tied to Brazil’s sanitation concessions and Argentina’s LNG terminal expansions, both of which demand reliable measurement under harsh process conditions.

Competitive Landscape
Market concentration is moderate. Emerson’s purchase of Flexim extends its ultrasonic reach, while the SICK-Endress+Hauser joint venture pools 800 specialists to accelerate gas analytics. ABB widened smart-building access through a wiring-accessory buy in China, improving channel coverage for low-voltage flow products used in HVAC balancing.
Strategic themes now favor vertical integration of hardware, software, and services. Ecolab’s flow intelligence platform demonstrates 15% water savings, showing why data-as-a-service unlocks sticky revenue in a hardware-heavy domain. Baker Hughes off-loaded its instrumentation arm to Crane Company for USD 1.15 billion, sharpening its energy transition roadmap while giving Crane a diversified sensor offering.
Innovation pipelines revolve around AI-assisted diagnostics, silicon photonics for multi-parameter sensing, and additive-manufactured flow bodies that reduce pressure loss. Emerging MEMS specialists tap biopharma growth with sterile single-use chips, and IoT platform players bundle predictive analytics that spot fouling before it degrades throughput. Competitive intensity will hinge on how effectively firms embed cybersecurity and analytics without bloating total cost of ownership.
Flow Sensors Industry Leaders
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Siemens AG
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Emerson Electric Co.
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ABB Ltd.
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Honeywell International Inc.
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Yokogawa Electric Corporation
- *Disclaimer: Major Players sorted in no particular order

Recent Industry Developments
- June 2025: Chart Industries and Flowserve agreed to a USD 19 billion all-stock merger that broadens aftermarket coverage for flow equipment.
- June 2025: Baker Hughes sold its Precision Sensors and Instrumentation business to Crane Company for USD 1.15 billion.
- March 2025: ABB acquired Siemens’ Wiring Accessories unit in China, adding distribution in 230 cities.
- February 2025: DwyerOmega bought Process Sensing Technologies, including FCI thermal mass flowmeters, to deepen penetration in chemical and pharma segments
Global Flow Sensors Market Report Scope
Flow sensors are the devices that are used to measure the flow rate, often for fluid. These sensors are usually a part of a flow meter, which can record the flow rate. Global flow sensors are segmented by type: liquid and gas. IT is differentiated by technology: Coriolis, differential flow, ultrasonic, vortex, and other technologies. Different industries, like oil and gas, water and wastewater, paper and pulp, chemical, power generation, food and beverage, are using flow sensors to strengthen their growth rate in respective fields.
By Type | Liquid | |||
Gas | ||||
By Technology | Coriolis | |||
Differential Pressure | ||||
Ultrasonic | ||||
Vortex | ||||
Thermal | ||||
Magnetic | ||||
By Installation Type | Inline | |||
Clamp-on | ||||
Insertion | ||||
By End-user Industry | Oil and Gas | |||
Water and Wastewater | ||||
Chemical and Petrochemical | ||||
Food and Beverage | ||||
Power Generation | ||||
Pulp and Paper | ||||
Pharmaceuticals | ||||
Other Industries | ||||
By Geography | North America | United States | ||
Canada | ||||
Mexico | ||||
South America | Brazil | |||
Argentina | ||||
Rest of South America | ||||
Europe | United Kingdom | |||
Germany | ||||
France | ||||
Italy | ||||
Spain | ||||
Nordics | ||||
Rest of Europe | ||||
Middle East and Africa | Middle East | Saudi Arabia | ||
United Arab Emirates | ||||
Turkey | ||||
Rest of Middle East | ||||
Africa | South Africa | |||
Egypt | ||||
Nigeria | ||||
Rest of Africa | ||||
Asia-Pacific | China | |||
India | ||||
Japan | ||||
South Korea | ||||
ASEAN | ||||
Australia | ||||
New Zealand | ||||
Rest of Asia-Pacific |
Liquid |
Gas |
Coriolis |
Differential Pressure |
Ultrasonic |
Vortex |
Thermal |
Magnetic |
Inline |
Clamp-on |
Insertion |
Oil and Gas |
Water and Wastewater |
Chemical and Petrochemical |
Food and Beverage |
Power Generation |
Pulp and Paper |
Pharmaceuticals |
Other Industries |
North America | United States | ||
Canada | |||
Mexico | |||
South America | Brazil | ||
Argentina | |||
Rest of South America | |||
Europe | United Kingdom | ||
Germany | |||
France | |||
Italy | |||
Spain | |||
Nordics | |||
Rest of Europe | |||
Middle East and Africa | Middle East | Saudi Arabia | |
United Arab Emirates | |||
Turkey | |||
Rest of Middle East | |||
Africa | South Africa | ||
Egypt | |||
Nigeria | |||
Rest of Africa | |||
Asia-Pacific | China | ||
India | |||
Japan | |||
South Korea | |||
ASEAN | |||
Australia | |||
New Zealand | |||
Rest of Asia-Pacific |
Key Questions Answered in the Report
What is the current size of the flow sensors market?
The global flow sensors market stands at USD 9.11 billion in 2025 and is set to reach USD 12 billion by 2030.
Which technology segment is growing the fastest?
Ultrasonic flow sensors post the highest 7.11% CAGR through 2030 thanks to non-invasive clamp-on retrofits and improved signal processing.
Why are water utilities investing in flow sensors?
Smart-water mandates push utilities to cut non-revenue water and modernize aging pipelines, driving a 7.24% CAGR in the water and wastewater segment.
How do semiconductor shortages affect the market?
Extended lead times for microcontrollers delay production of IIoT-enabled meters, shaving 0.6 percentage points from forecast CAGR.