"We see this as the phoenix being reborn from the ashes," ADS' research and development manager Lionel Ridosz told FoodProductionDaily.com. "The old machinery has been around for more than 10 years so we thought it was time to redesign it, and to see where we could make the biggest energy savings in order to meet the demand that we expect to see from our clients for 'greener' machines." According to ADS, companies are looking for new ways of proving to their customers that they are taking environmental issues seriously. Proving that the bottles they use for their products are made in as an environmentally-friendly way as possible is one way of doing so, it said. "But for the bottle makers themselves, the redesigned machines are more about the energy - and therefore cost - savings that can be made." The company explained that blow moulding of bottles needs air to be produced at high pressure, which uses a lot of energy. ADS said it has managed to reduce energy consumption by 28 per cent for 40 bar air pressure by redesigning the system. At a pressure of 7 bar, it has reduced energy consumption by 63 per cent. The new machines are also more compact (1.5m shorter than before), because more of the electrical equipment is incorporated within the main chassis, said Ridosz. This has also helped reduce the amount of wasted energy given off by the electrical cables, he added. Ridosz said that the heating elements within the machinery had also been improved to ensure that as much of the heat as possible was absorbed by the bottle and not wasted. The company has spent around six months redesigning each machine on the computer, with another month or so spent on building the new machine, and the first two have already been sold to clients in the UK and Africa. ADS produces around 25 machines a year, many of them made to specific requests from small-scale converters, and Ridosz said that maintaining this high level of flexibility had been a key component of the redesign. "There is a great deal of competition in the European market, and we have made a name for ourselves by being versatile and producing lines that can be adapted to a variety of different bottle designs." "That was why we wanted to make sure that our new-look machines remained 'future proof' and could be easily adaptable to new advances in technology and design, since they represent a significant investment for our clients."