Overview 

Transforming whisky cask monitoring through ultrasonic technology bringing digital innovation to one of Scotland’s most traditional industries. 

Background 

Inspectahire Instrument Co. Limited, headquartered in Aberdeen, is a leading provider of specialist inspection services and equipment with over 40 years of experience. Operating across oil & gas, renewables, and infrastructure, the company is recognised for its expertise in hazardous and confined environments where safety and precision are critical. 

Inspectahire has built a strong reputation delivering inspection solutions for complex and hazardous environments. As part of its growth strategy, the company has diversified beyond traditional energy markets into sectors such as whisky maturation, supporting efficiency and net-zero ambitions. 

Scotland’s whisky industry is globally significant, contributing over £5 billion annually. However, it relies on traditional, manual processes that have remained largely unchanged for centuries. Recognising an opportunity to modernise this sector, Inspectahire partnered with the University of Strathclyde developing an innovative ultrasonic device to transform whisky cask monitoring, bringing digital innovation to one of Scotland’s most traditional industries. 

Interface played a pivotal role by providing an Advanced Innovation Voucher, acting as the catalyst that initiated this industry-academic collaboration. 

The Challenge 

Monitoring liquid levels in whisky casks during maturation presents a longstanding industry challenge. 

Traditional methods involve physically moving and opening heavy casks (often hundreds of kilograms) for manual “dipstick” measurement and using pressure-based techniques with limited accuracy resulting in a process which is labour-intensive, time-consuming, inefficient, and risky, often resulting in product loss and increased carbon emissions. 

Inspectahire identified the need for a non-invasive, accurate, and safe solution capable of measuring liquid levels without moving or opening casks – something never previously achieved at scale. 

The Solution 

In collaboration with the University of Strathclyde, with the help of an Advanced Innovation Voucher and supported by a KTP, Inspectahire developed a portable ultrasonic measurement device capable of determining whisky levels inside sealed wooden casks. 

Key features include: 

• Non-invasive measurement through the cask wall  
• Handheld, battery-powered design for ease of use  
• Real-time digital readings via integrated display  
• Compatibility with horizontal and vertical casks  
• Safe operation in hazardous bonded warehouses  

The device uses advanced ultrasonic transducers and custom signal-processing algorithms to overcome challenges such as variable wood density, curvature, surface coatings and moisture content differences.  

Extensive field trials conducted with distilleries and the Scotch Whisky Research Institute (SWRI) validated performance across hundreds of casks under real-world conditions. 

This innovation delivers a step-change in whisky cask management replacing centuries-old manual processes with a safe, efficient, and sustainable digital solution, bridging tradition and modern technology. 

Inspectahire intend to deliver the technology as both a product and a service. The company will supply the instrument for purchase or hire, and offer on-site cask monitoring, operator training, maintenance, and data management services. The solution enables distilleries to conduct regular, accurate, and safe in-situ measurements, reducing manual handling, carbon emissions, and product loss while improving efficiency and safety. 

The device is approaching commercial deployment, with strong interest from several distilleries. 

Company Benefits 

The collaboration has delivered significant commercial and strategic benefits for Inspectahire: 

Business Growth & Diversification 

• Entry into the whisky industry from oil & gas  
• £40,000 additional turnover from new clients  
• Expanded customer base including distilleries and warehouse operators  

Innovation & Market Positioning 

• Positioned as a technology leader in whisky cask monitoring  
• Strong commercial interest ahead of product launch  
• New opportunities in international markets such as the tequila industry  

Operational Impact 

• Strengthened industry relationships  
• Increased brand visibility in a high-value sector  
• Creation and safeguarding of skilled jobs  

Interface’s early support was critical in de-risking the initial collaboration, enabling Inspectahire to access academic expertise and accelerate innovation. 

Academic Benefits 

The partnership has also delivered major benefits to the University of Strathclyde: 

Research & Innovation 

• Advancement of ultrasonic sensing in complex materials  
• Access to real-world industrial data and testing environments  
• Peer-reviewed publication and international conference presentations  

Funding & Capacity Building 

• Support for a postdoctoral research position through the KTP  
• Strengthened capability in applied research and knowledge exchange  

Recognition & Impact 

• KTP awarded outstanding grade  
• Dr Dayi Zhang awarded Interface Innovator of the Future 2025 and University of Strathclyde Strategic Themes R&KE Impact Award (August 2025)  
• Enhanced global reputation in applied ultrasonics  

Teaching & Skills Development 

• Integration of project insights into undergraduate teaching  
• Development of researcher skills aligned with industry needs  

Next Steps 

Building on this success, Inspectahire and the University of Strathclyde are progressing from successful technology development and certification into commercial rollout and further innovation. 

Short-Term (2026–2027) 

• Expand commercial deployment across whisky warehouses and distilleries 
• Grow product sales, hire and on-site cask monitoring services 
• Strengthen partnerships with whisky producers in Scotland and internationally 
• Develop next-generation devices incorporating time-of-flight ultrasonics 
• Recruit additional specialist capability, including AI expertise  

Medium-Term (2027–2028) 

• Scale commercial adoption across the whisky sector 
• Develop wireless data transfer and automated monitoring capabilities 
• Introduce AI-driven analytics and enhanced data management 
• Explore further Knowledge Transfer Partnership activity to support next-generation technology development 
• Progress adaptation of the technology for tequila, other spirits industries and wider industrial fluid-monitoring applications 

Future Innovation 

• Develop connected and automated cask-monitoring systems capable of supporting large-scale warehouse operations 
• Apply AI and data analytics to support predictive monitoring and improved asset management 
• Expand the technology into international spirits markets and other sectors requiring safe, non-invasive liquid-level measurement 

Interface’s Role 

Interface was instrumental throughout this journey: 

• Initiated the collaboration through an Advanced Innovation Voucher  
• Enabled access to academic expertise and facilities  
• Helped de-risk early-stage innovation  
• Supported the development of a long-term strategic partnership with a Knowledge Transfer Partnership (KTP)  

This demonstrates how Interface’s support can catalyse innovation, unlock collaboration, and drive real economic and societal impact transforming ideas into commercially viable solutions.