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Case Study

Inspectahire + University of Strathclyde

Develop a portable fluid level measuring device to monitor cask contents whilst in situ.                                                                             

measurement, whisky, casks.

Awards and Achievements

KTP Final Grade: A ⭐⭐⭐⭐⭐

The project was awarded the grade of "Outstanding" by the KTP Grading Panel for its achievement in meeting KTP's objectives.

Innovator of the Future 🏆

KTP Associate Dr Dayi Zhang won the Innovator of the Future award at the 2025 Scottish Knowledge Exchange Awards.

Inspectahire

Inspectahire Instrument Co. Limited (Inspectahire) has been in business in its current form since 1981, the original business commencing in 1964. It is a family owned private company headquartered in Scotland. Originally focussing on remote visual inspection instrument hire to the Civil Engineering market, we broadened our offering with staff able to undertake inspections both within the UK and overseas. We undertook our first jobs offshore in 1981 as well as undertaking an inspection in Khartoum North Power Station prior to its handover in 1981 as well. 

"Inspectahire have been fortunate to undertake a product development through the KTP programme. The team throughout the process have been very supportive and encouraging. The desire to enable academic resources to be accessible and utilised by an SME was very evident and meant we were able to turn an identified need into a solution which is a game changer for a significant Scottish industry which we couldn’t have done otherwise." - Cailean Forrester, Managing Director 

 

Inspectahire Logo

What was the need?

The Challenge

The whisky industry faces significant inefficiencies and risks in measuring cask volumes, often requiring operations teams to travel to remote facilities. Warehouses housing thousands of casks, some stacked up to eight high, necessitate the resource-intensive and risky task of moving 600-pound casks with forklifts. This process incurs substantial labour, fuel, vehicle, and maintenance costs. Additionally, multiple measurements over a cask's lifespan further increase resource consumption. The risks to personnel, equipment, and casks are considerable, with accidental drops or damage leading to costly product leaks and significant economic losses. Detecting whisky leaks and emissions can mitigate these economic and environmental impacts, improving yield and minimising safety incidents. Currently, distilleries use dipsticks for level measurements, requiring the relocation of heavy casks from high shelving to testing facilities, risking human safety and necessitating cask openings. Some distillers use pressure sensors inside casks, where pressure changes correspond to whisky level shifts. However, this method is sensitive to temperature and vibration, presenting limitations in accuracy and suitability.

What did we do?

The Solution

The project is to develop a prototype device for monitoring whisky levels in casks in-situ, necessitating a thorough understanding of technical, commercial, and regulatory aspects, including CE and ATEX compliance. This involves creating a prototype equipped with an ultrasonic transducer connected to a battery-powered unit with a display. The inspection engineer can use this device to scan the surface of the cask, accurately identifying the liquid level without needing to relocate or open the casks.

Engineering tasks include crafting efficient ultrasonic circuits, digitising signals, implementing detection algorithms, designing a user-friendly interface, integrating an embedded computer, and packaging the system into a handheld unit. Collaboration with Inspectahire and external partners is being carried out to validate the prototype's performance through field trials and customer feedback, guiding design improvements for subsequent iterations. Additionally, pre-certification testing for CE and ATEX compliance is being conducted to ensure the device meets regulatory standards. The project also produced one journal paper and one international conference presentation, documenting its progress and findings, contributing to the academic and industrial knowledge base.

What changed?

The Impacts and Benefits

Impacts for the Company

The project is set to significantly impact Inspectahire, increasing revenue from existing clients and attracting new ones. Expected profits of £100,000 in the first year, rising to £1,000,000 by the fifth year, demonstrate strong economic potential. The project will also create jobs, including a Marketing and Business Development Lead and upskilling three technicians in ultrasonic testing.

Inspectahire will use the new portable device to survey whisky casks in-situ, expanding their services and boosting revenue. Positive feedback from the Scotch Whisky Research Institute, which will help introduce the device to distilleries, further supports growth prospects.

To support expansion, Inspectahire plans to hire a Marketing and Business Development Lead to drive sales and technician upskilling. As the client base grows, additional technicians will be recruited to meet demand.

Collaborations with the University of Strathclyde will leverage academic outcomes, such as optimised ultrasound frequency and post-processing methodologies, for further research and application. These findings will benefit both the company and the university. The project’s results will also serve as case studies and teaching materials, enhancing the practical skills and industry readiness of university students.

 

Impacts for the Academic Team

The KTP academic outcomes, including optimised ultrasound excitation frequency and post-processing methodologies to reduce signal loss, significantly benefit further research on wood structures using ultrasound transducers. The Associate’s work transcends practical applications, producing academic contributions that advance understanding of ultrasound properties in wood. The research findings, documented in a paper submitted to a high-quality journal, have far-reaching implications, potentially impacting not only the whisky industry but also research on other wooden products, such as bridges and heritage buildings. These outcomes underscore the broader significance and diverse applications of the project's impacts, demonstrating its value to both academia and industry.

 

Impacts for the KTP Associate 

I expanded my professional network by attending courses and three KTP conferences, which featured participants from diverse fields such as business and design. This exposure helped me explore innovations beyond my research field. CPD courses like Innovation Strategy provided insights into the challenges of translating research into successful products. Using the innovation canvas tool, I revised the project strategy and gained insights into experience, finance, and operations. The Oxford Leading Strategic Projects Programme equipped me with skills to implement and lead strategic projects amidst uncertainties and complexities, addressing issues of scale, pace, people, power, and politics. By applying the KTP project to my coursework, I deepened my understanding of complexities and risks, re-evaluated success and performance, enhanced the KTP project, and developed principles for future projects.

Unlike typical research projects focused on early-stage innovations, this project involved creating a device requiring qualifications and certifications, such as CE mark tests and safety in hazardous environments. I learned about these regulations through training and interactions with external partners. Additionally, I developed engineering skills, including understanding ultrasound propagation in various wood types and whisky casks, signal processing on low-power microcontrollers, and system engineering, which will benefit my future career.

The People

Meet the Team

Dr Dayi Zhang

KTP Associate

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Professor Gordon Dobie

Knowledge Base Supervisor

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John Rennie

Company Supervisor

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