This paper describes a methodology for measuring rheological flow properties in-line, in real-time, based on simultaneous measurements of velocity profiles using an ultrasound velocity profiling (UVP) technique with pressure difference (PD) technology. The methodology allows measurements that are rapid, non-destructive and non-invasive and has several advantages over methods presented previously. The set-up used here allows direct access to demodulated echo amplitude data, thus providing an option to switch between time domain algorithms and algorithms based on FFT for estimating velocities, depending on the signal-to-noise ratio (SNR) and time resolution required. Software based on the MATLAB® graphical user interface (GUI) has been developed and provides a powerful and rapid tool for visualizing and processing the data acquired, giving rheological information in real-time and in excellent agreement with conventional methods. This paper further focuses on crucial aspects of the methodology: implementation of low-pass filter and singular value decomposition (SVD) methods, non-invasive measurements and determination of the wall positions using channel correlation and methods based on SVD. Measurements of sound velocity and attenuation of ultrasound in-line were introduced to increase measurement accuracy and provide an interesting approach to determine particle concentration in-line. The UVP-PD methodology presented may serve as an in-line tool for non-invasive, real-time monitoring and process control. © 2007 Elsevier Ltd. All rights reserved.