Stirling Distillery partners with scientists to develop aluminum packaging for whisky

Stirling Distillery has joined forces with scientists at Heriot-Watt University, UK, to develop aluminum packaging for whisky as an alternative to traditional glass bottles. 

At Heriot-Watt University, the researchers from the International Centre for Brewing and Distilling and Institute of Chemical Sciences have conducted tests to assess whether aluminum chemically interacts with whisky in a way that alters its flavor or raises safety concerns.

Kathryn Holm, head of communications and marketing at Stirling Distillery, says: “We want to make our distillery as sustainable as possible ahead of our first mature whisky being released in 2027. The whisky industry is looking at lots of ways to minimize its footprint. We’ve already undertaken a range of sustainability measures — packaging is one of the remaining areas where we can innovate and make an impact.”

“Glass has long been central to whisky’s image. It’s weighty and evokes the craftsmanship of the spirit. But it is also heavy to transport and relies on high recycling rates to reduce its environmental impact. Aluminum is lighter and widely recycled, so I asked the experts to investigate whether it’s a viable alternative.” 

Lower carbon option

The researchers have tested the spirit supplied by Stirling Distillery using nuclear magnetic resonance spectroscopy. The technique uses a magnet combined with radiofrequency waves to identify what a substance is made of by measuring how its atoms respond, and inductively coupled plasma mass spectrometry, which detects levels of metals in liquids.

Dr. David Ellis, assistant professor, School of Engineering and Physical Sciences, at Heriot-Watt University, says: “We know that certain organic acids naturally present in matured whisky can react with aluminum, which can lead to aluminum entering the liquid. If we stir samples with aluminum metal, the levels were well above what would be considered acceptable for drinking water.” 

According to the scientists, compounds such as gallic acid, which form during whisky maturation, were reduced or removed after prolonged contact with aluminum. In contrast, these reactions were much less pronounced in new make spirit, which has not yet developed the same chemical profile.

Finding the perfect liner 

Professor Annie Hill from Heriot-Watt University explains: “Any innovation has to respect the craft of whisky making while meeting the highest standards of safety. The aluminum cans we buy pulses and soup in have liners to protect the contents from metal contamination.”

“In this case, the liner within the can wasn’t sufficient to prevent aluminum from passing into the spirit. The next stage of this research would be to find a liner that can withstand high alcohol levels for a prolonged period of time without degrading.”

Hill shares that in the sensory testing, panelists could not distinguish between whisky stored in aluminum from whisky stored in glass.

“The changes detected in the laboratory didn’t translate into differences in aroma. That’s great news — if we can find an effective liner.”