Reinventing a Safety-Critical Classic

Part of the Cardiff Capital Region (CCR) Academic-Industry Partnerships (AIP) Programme, Barry-based Lion Laboratories is strategically advancing its flagship breathalyser product, the Alcoblow, through innovative design that seamlessly integrates modern functionality, enhanced usability, and optimised manufacturability.

The next-generation device, the Alcoblow+, delivers cutting-edge features including rechargeable power systems, advanced digital display technology, and streamlined assembly processes, all precisely engineered to capitalise on expanding market opportunities. With its sophisticated, user-centric design and advanced rapid prototyping methodologies, the project is successfully strengthening local employment whilst establishing the foundation for accelerated growth across global safety-critical markets.

The Company

Lion Laboratories has maintained industry leadership in alcohol testing technology for over two decades. As pioneers who introduced the first handheld alcohol pre-screener with the original Alcoblow, the company established a commanding presence in policing and workforce safety across Poland, Italy, Australia, and South Africa.

Today, Lion Labs continues to drive innovation leadership, leveraging distinguished academic partnerships to strategically evolve its market-leading product line. This approach ensures the company not only meets evolving user expectations but exceeds them, whilst strengthening its established reputation as the trusted choice for law enforcement and safety industries worldwide.

The Challenge

The original Alcoblow achieved remarkable success, with peak sales exceeding 15,000 units annually, establishing Lion Labs as the definitive market leader. As the industry matured and customer expectations evolved towards enhanced features like advanced screen readouts, sophisticated rechargeable battery systems, and streamlined calibration processes, Lion Labs identified a strategic opportunity to leverage these market developments.

Simultaneously, the company's forward-thinking approach recognised that maintaining technological leadership required transitioning from legacy electronic designs to next-generation components with superior supply chain reliability. This presented Lion Labs with an exciting dual opportunity: to reinvigorate distributor partnerships through innovation whilst simultaneously optimising manufacturing efficiency and profitability.

The Solution

Partnering with the distinguished Product Design and Research (PDR) team at Cardiff Metropolitan University, Lion Labs implemented a comprehensive 'Step-Jump-Leap' innovation framework to reimagine the Alcoblow. This sophisticated process generated three strategically differentiated concepts, ranging from enhanced iterations of the proven design to revolutionary new approaches that fundamentally reimagined form, functionality, and user experience.

Following extensive consultation with the company's valued distributor network, market feedback strongly validated the 'Step' approach—a sophisticated evolution of the established product—as the optimal pathway for market leadership and sustained growth.

This vision has been successfully developed into a fully specified, production-ready product incorporating premium features including high-resolution digital displays, convenient USB-C charging capability, and ergonomically optimised grip design with precision sampling alignment for superior usability. Advanced high-fidelity 3D printed prototypes have enabled comprehensive real-world validation, precise fit verification, and valuable stakeholder feedback integration.

The Results

• Innovation-driven market leadership: The Alcoblow+ masterfully combines comprehensive user insights, manufacturing excellence, and cutting-edge technology into a refined, instantly recognisable product, strategically positioned to recapture and expand market share across global safety sectors.
• Enhanced local economic impact: The redesign has successfully secured and strengthened five skilled assembly positions at Lion Labs' Barry facility, demonstrating the company's commitment to local workforce development and regional manufacturing excellence.
• Advanced technology integration: Lion Labs has successfully implemented state-of-the-art 3D printing and rapid prototyping capabilities into its R&D operations, dramatically accelerating innovation cycles and establishing a foundation for increasingly agile product development.
• Production readiness and investment commitment: With precision injection moulding specifications and optimised printed circuit board layouts finalised, the next stage encompasses sophisticated electronic integration, advanced screen development, and comprehensive pre-production validation. Lion Labs is investing £30k+ in specialised tooling, reinforcing its commitment to maintaining premium production standards in South Wales.
• Market expansion and growth trajectory: Through the strategic modernisation of the Alcoblow, Lion Labs is confidently positioned not only to return to previous peak sales volumes (15–20k units annually), but to expand into high-value adjacent sectors including mining operations, comprehensive workforce monitoring systems, and specialised international safety-critical applications.
• R&D excellence and partnership success: This collaboration has proven the exceptional value of user-centred design methodology and rapid prototyping in revitalising industry-leading products. Lion Labs is now substantially increasing R&D investment and looks forward to continued innovative development of the Alcoblow+ in partnership with PDR.