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In a move that blends centuries-old craftsmanship with cutting-edge robotics, spirits giant Bacardi has unveiled a new recruit at its John Dewar & Sons maturation site: a four-legged robot dog tasked with “sniffing out” ethanol leaks.
Named “Royal Bark-la” — a playful nod to the company’s Royal Brackla single malt — the robot is the centerpiece of a first-of-its-kind trial for the Scotch whisky industry.
The project aims to determine if autonomous technology can identify small, costly leaks in aging warehouses more efficiently than traditional manual inspections.
Guarding the ‘Angel’s Share’
In the world of Scotch, the “Angel’s Share” refers to the natural evaporation of alcohol that occurs as whisky matures in oak casks. While some loss is expected, unexpected leaks can lead to significant waste. Across the industry, evaporation accounts for the equivalent of roughly 440,000 casks every year.
Traditionally, monitoring these thousands of barrels has been a labour-intensive process, relying on visual cues and manual checks that are prone to human error. By deploying a Boston Dynamics “Spot” robot, Bacardi hopes to create a repeatable, data-driven alternative.
The tech behind the “bark”
The trial is a collaborative effort between Bacardi, the National Manufacturing Institute Scotland (NMIS), and the Scotch Whisky Research Institute (SWRI).
Engineers at the NMIS Digital Process Manufacturing Centre in Irvine developed a custom robotic sensing kit specifically for the project.
The system features a 3D-printed arm equipped with highly sensitive ethanol vapour sensors. As Royal Bark-la trots methodically along a pre-determined path through the Glasgow warehouse, the sensors “sniff” the air, mapping vapor levels in real-time. Unlike human inspectors, the robot is not distracted by the vast environment and can provide consistent readings across every aisle.
“Craftsmanship and heritage remain at the heart of our production,” said Angus Holmes, whisky category director at Bacardi. “But there is also great potential for innovation and technology to support the industry to become more efficient and data-driven.”
A future beyond the warehouse
While the trial is currently in the “proof of concept” stage, the early results have been promising. Bacardi led the baseline testing to determine “normal” vapour levels, allowing the robot to flag any anomalies that suggest a leaking cask.
Beyond safeguarding whisky, the National Manufacturing Institute Scotland believes this technology has far-reaching implications. The ability to detect gas or liquid leaks autonomously could be applied to the chemical, energy, and broader manufacturing sectors, where safety and waste reduction are paramount.
The next phase of the project may see the sensors embedded directly into the robot’s body rather than mounted on an external arm, further increasing the unit’s durability and functionality in tight warehouse spaces.
As the industry looks to the future, Royal Bark-la represents a shift toward “Whisky 4.0.” For the team at John Dewar & Sons, the robot has quickly become a mascot for a new era—one where high-tech “canines” help ensure that the only whisky leaving the barrel is the portion destined for the bottle.
ethanol leak detection robotics vapour sensors whisky
Angus Holmes
Bacardi John Dewar & Sons National Manufacturing Institute Scotland NMIS Scotch Whisky Research Institute SWRI
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