SmartValveAI – A Leap Forward in Condition Monitoring
Carten Controls Ltd, a global leader in ultra-high purity valve solutions, is partnering with Walton Institute at South East Technological University to bring predictive intelligence into manufacturing. This collaboration is centred on the development of SmartValveAI, a real-time condition monitoring platform designed to enable algorithmic predictive maintenance across critical flow systems.
Supported by the Enterprise Ireland Innovation Partnership Programme, the project aims to reduce the need for scheduled annual valve maintenance by providing actionable insights on component performance—optimising operational uptime and ensuring the integrity of every batch produced.
With batch values often reaching into the millions of euros, the potential impact of this technology on process safety, cost-efficiency and product quality is transformative.
“This project has the potential to revolutionise predictive maintenance in pharmaceutical and other settings. We are delighted to work with a great Waterford business delivering world-class solutions and local jobs for over 40 years.”
Liam Fitzgerald, ICS Technology Gateway Manager, Walton
Supporting Advanced Manufacturing and Regional Jobs
The initiative began in 2023 when Carten Controls approached the ICS Technology Gateway at SETU’s Walton Institute to explore new innovation pathways. Over several months, and in collaboration with researchers from the Programmable Autonomous Systems (PAS) division, the SmartValveAI concept took shape
The SmartValveAI system is expected to reduce operating costs, avoid unnecessary interventions, and shorten or eliminate costly plant shutdowns. The technology will give operations and maintenance teams greater visibility and control, supporting smarter, data-led decision-making in pharmaceutical and other environments.
Launched in late 2024, the two-year project represents the most ambitious evolution in Carten’s core technologies since entering the biopharmaceutical sector. By embedding artificial intelligence into its valve systems, Carten is not only enhancing its product offering, but also helping to secure the long-term future of its Waterford site.
“This is a step change in the technology within our valves. The importance of this project in securing the Waterford site through modern business models cannot be overstated.”
Brendan Phelan, Technology Manager, Carten Controls
Background
Carten Controls Ltd has been delivering high-quality jobs and advanced engineering expertise in the south east since 1981. This project has attracted strong interest from its parent company, Fujikin Incorporated (Japan), highlighting the potential for global adoption of this next-generation platform.
This project is part-funded by the Enterprise Ireland Technology Gateway Programme, co-financed by the Government of Ireland and the European Union through the ERDF Southern, Eastern & Midland Regional Programme 2021–2027.