01 / Features — The Operating System for Spirits

Every cask in the yard has a twin in the machine.

Stop running your bond on spreadsheets. DistilleryOS unites 3D Digital Twin warehousing, StaveSage™ kinetic maturation, HMRC Notice 197 & Notice 207 compliance, Contract Bottling Split-BOM, and BRCGS Issue 9 traceability under one flat £350/month license.

01.1 — 3D Warehouse Digital Twin

3D Warehouse Digital Twin & Cask Management

Your whole estate, rendered live in 3D. Every bond on one screen with its cask count and OIML R22 LPA — click a door and walk in, or explore Cask Management & Broker Portals.

  • Estate overview — every bond, one screen
  • Enter a warehouse, select a cask down to stow & tier
  • Amber band shows live fill level (LPA)
DistilleryOS Digital Twin estate overview in admin mode: two 3D bonded warehouses, Bond 1 The Crendon and Bond 2 The Red Shed, with live cask counts and total LPA in the HUD.
Digital Twin / Estate Overview

01.2 — Inside the Bond

Walk the racks without the forklift

Inside each bond, every cask is rendered at its recorded rack position — pallet stacks in The Crendon, steel racking in The Red Shed. Find a cask by ID and the twin takes you to it.

  • Casks rendered at their rack positions
  • Pallet stacks & steel racking, modelled
  • Find any cask by ID, instantly
Inside Bond 1 The Crendon in the DistilleryOS Digital Twin: oak casks rendered on pallet stacks at their recorded positions, with the live cask count and LPA in the header.
Digital Twin / Bond 1 — The Crendon

01.3 — The Record

One cask, one record

Volume, strength, bulk litres, angels' share and a global location down to the tier — with regauge, move, sample and bottle a click away. The twin is the bond, not a copy of it.

  • Live volume, strength & bulk litres (L)
  • Global location down to the tier
  • Regauge · move · sample · bottle
DistilleryOS cask record DEMO-2026-0003, a Peated Islay Malt: 283.50 litres of pure alcohol at 58.30% ABV, global location CRENDON-1-1-2-2, with regauge, move, sample and bottle operations.
Cask Record / One Record

01.4 — StaveSage™ Kinetic Maturation

StaveSage™ Kinetic Maturation & Financial Peak

Our StaveSage™ engine runs a 10-to-15-year physico-chemical Arrhenius projection per cask — charting Angel's Share evaporation, ABV drift, wood porosity, and gross yield. Try the live StaveSage™ Kinetic Calculator.

  • LPA loss, ABV drift & gross yield, charted
  • Climate archetype, wood species & char modeling
  • Export investor-ready PDF projections
DistilleryOS StaveSage Predictive Engine: a ten-year projection for one cask charting LPA loss, ABV drift and gross yield, with bottle price, bottle size and annual APY inputs and a PDF export.
StaveSage™ / Kinetic Projection

01.5 — Flavour

Predicted Flavour DNA

Where is this cask heading? The twin extrapolates a year-ten sensory profile from the wood and the liquid — caramel to feinty, quantified on an eight-vector radar.

  • Year-10 flavour extrapolation
  • Eight-vector sensory radar
  • Caramel to feinty, quantified
DistilleryOS Predicted Flavour DNA: a year-ten radar and bar profile for one cask scoring caramel, vanilla, fruit, dried fruit, chocolate, feinty and spice notes.
Flavour DNA / Year 10

01.6 — Contract Bottling & Split-BOM

Liquid Formulations & Split-BOM Dry Goods Depletion

Built for high-throughput contract bottlers and rectifiers. Manage versioned Distillation vs Compounding liquid recipes alongside Split-BOM packaging that cleanly segregates warehouse-supplied (AM_STOCK) components from Customer Free-Issue dry goods. Explore Contract Bottling & BOM.

  • Distillation vs Compounding liquid formulations & botanicals
  • AM_STOCK vs Customer Free-Issue Split-BOM billing
  • Real-time dry goods lot gates & multi-pallet export packing lists

01.7 — BRCGS Issue 9 / SALSA / HACCP

Floor Tablet CCP Interlocks & SHA-256 Batch Dossiers

Bottling lines cannot start until mandatory Critical Control Point (CCP) checks pass on the floor tablet. Rinser pressure/allergen validations, GQA ingredient water lab tests, and intake photo dockets compile automatically into a SHA-256 tamper-evident Batch Release Dossier.

  • Floor tablet CCP interlocks for rinser & water lab
  • Intake photo dockets & forward/backward lot genealogy
  • SHA-256 tamper-evident Batch Release Dossiers

01.8 — HMRC Notice 197 & Notice 207

Immutable Daybook, W5 Two-Invoice Split & Notice 207 Drawback

Every regauge, vatting, bottling run, and dispatch writes directly to the HMRC Notice 197 bonded daybook. Home-market releases automatically execute the W5 Two-Invoice Split (Xero Account 820 for 3PL fees and Account 200 for pass-through excise duty), while spoilt or destroyed stock generates sealed Notice 207 Duty Drawback & Destruction Certificates. See Notice 197 Compliance.

  • Immutable Notice 197 Bonded Daybook & W1/W5 returns
  • W5 Home-Market Two-Invoice Split on Accounts 820 / 200
  • Notice 207 Duty Drawback & Sealed Destruction Certificates

01.9 — Commerce

Shopify native

Orders sync instantly. Stock levels push back in real time. The shop can never sell a bottle the bond doesn't hold — no more overselling.

  • Two-way sync — orders in, stock out
  • Duty-paid & in-bond channels
  • Xero accounting sync built in

01.10 — Dispatch

High-speed dispatch

Mobile scanning for pickers, automatic label generation for Royal Mail & DHL, and 100% accurate fulfilment — because every pick is checked against the record.

  • Barcode scan-to-pick, zero mispicks
  • Royal Mail & DHL labels, automatic
  • 3PL dispatch hub for client stock

01.11 — Command

One console for the whole bond

Casks under bond, portfolio LPA, fulfilment velocity and a living operational timeline — the numbers your accountant, your warehouse keeper and HMRC all agree on, on one screen.

  • Casks under bond & portfolio LPA, live
  • Living operational timeline
  • Unlimited users — £350/month flat
DistilleryOS operations dashboard: 3,116 casks under bond, total portfolio LPA, fulfilment velocity, a living operational timeline and the operational inbox.
Console / Operations — Live