E-268 Pool Nation Podcast - From Napkin to Shelf: How BioLab Creates the Chemicals That Run Your Pools

The Hidden World of Pool Chemical Innovation

Ever wondered what goes into creating the chlorine tablets, algaecides, and sanitizers that keep pools sparkling clean? Most pool professionals simply grab products off the shelf without considering the months or even years of research, development, and testing that brought those chemicals to market. In a fascinating episode of the Pool Nation Podcast, hosts Edgar De Jesus, John JJ, and Zach sat down with BioLab's Alicia Stevens and Ted Lawrence to pull back the curtain on this hidden world of chemical innovation.

This isn't just another product spotlight – it's a deep dive into the science, strategy, and sheer complexity of bringing new pool chemicals from napkin sketch to store shelf. For an industry that relies so heavily on chemical solutions, understanding this process offers valuable insights into why certain products work the way they do, why innovation takes time, and what the future might hold for pool water treatment.

The Journey Begins: From Problem to Solution

Chemical innovation in the pool industry doesn't happen in a vacuum. It starts with real problems that pool professionals and homeowners face every day. Whether it's a new type of algae that's proving resistant to traditional treatments, environmental regulations that require reformulation, or simply the need for more user-friendly products, every new chemical begins with identifying a genuine need in the market.

The initial concept phase involves extensive market research, talking to distributors, pool service professionals, and end users to understand pain points. BioLab's approach emphasizes this customer-centric development, ensuring that new products address real-world challenges rather than just theoretical improvements.

Today we're talking to Alicia Stevens and Ted Lawrence from Biolab. Today we're gonna go behind the scenes with them to talk about something that most people in our industry never get to see. The process of creating new chemicals and products from napkin to in-store shelf. This is a story of innovation in our industry.

— Edgar De Jesus, Pool Nation Podcast

The Science Behind the Solutions

Once a concept is identified, the real scientific work begins. Chemical formulation is part art, part science, requiring deep understanding of chemistry, biology, and physics. The team must consider how different ingredients interact not just with pool water, but with existing treatment regimens, various pool surfaces, and equipment.

The formulation process involves countless iterations, testing different concentrations, delivery methods, and stabilizers. Each variation must be evaluated for effectiveness, safety, stability, and compatibility with other pool chemicals. This phase alone can take months or even years, especially for breakthrough products that require entirely new approaches.

Environmental considerations have become increasingly important in modern chemical development. Formulators must balance efficacy with environmental impact, considering factors like biodegradability, aquatic toxicity, and the broader ecological footprint of their products.

Testing, Testing, and More Testing

Before any new chemical can hit the market, it must undergo rigorous testing that makes most quality control processes look simple by comparison. This testing happens on multiple levels and in various environments to ensure the product performs consistently across different conditions.

Laboratory testing comes first, where controlled conditions allow scientists to evaluate basic performance metrics. But real-world testing is where products either prove themselves or go back to the drawing board. This involves partnerships with pool service companies, retail stores, and even homeowners who agree to test products under actual use conditions.

Field testing reveals issues that laboratory conditions simply cannot replicate. Factors like varying water chemistry, different pool construction materials, regional climate differences, and user behavior all impact how a chemical performs in practice. These real-world insights often lead to formula adjustments or entirely new application methods.

The thing that stinks is the only thing that I can find is those vans from like budget that have the wall behind the seats. So you can't even recline the seats. And I'm suffering. Like I looked at RVs. I looked like, I just looked at every, and just nothing.

— Edgar De Jesus, Pool Nation Podcast

Regulatory Hurdles and Compliance

Perhaps no aspect of chemical development is more complex or time-consuming than navigating regulatory requirements. Pool chemicals are subject to extensive federal, state, and sometimes local regulations that govern everything from ingredient disclosure to packaging requirements.

The EPA registration process alone can take 12-18 months or longer, requiring extensive documentation of efficacy data, safety studies, environmental impact assessments, and manufacturing processes. Each state may have additional requirements, and some ingredients that are acceptable in one region may be restricted in another.

International markets add another layer of complexity, as companies looking to export must comply with different regulatory frameworks in each target country. This regulatory maze often influences product development decisions early in the process, as formulators must consider not just what works best, but what can realistically gain approval in key markets.

From Lab Bench to Manufacturing Scale

Successfully scaling a chemical formula from laboratory quantities to full manufacturing volumes presents its own set of challenges. What works perfectly in a beaker may behave entirely differently when produced in thousand-gallon batches. Manufacturing scale-up requires careful attention to mixing procedures, temperature control, quality control systems, and packaging considerations.

Quality control becomes even more critical at manufacturing scale. Every batch must meet strict specifications for active ingredient concentration, pH, stability, and physical properties. Sophisticated testing equipment and procedures ensure consistency from the first batch to the thousandth.

Packaging decisions impact both product performance and user experience. The container must protect the chemical from degradation while providing convenient, safe dispensing for end users. Even seemingly simple decisions like bottle shape or cap design can significantly impact product success in the marketplace.

I'm a little everywhere, but yeah, it's all fun. So it's all in good spirit to help the industry help us get better.

— Ted Lawrence, Pool Nation Podcast

Market Launch and Ongoing Innovation

Launching a new chemical product requires coordinated efforts across multiple departments and distribution channels. Sales teams need training on product benefits and proper application, marketing materials must be developed, and distribution partners need to understand how the new product fits into their existing inventory.

But the innovation process doesn't end at launch. Successful chemical companies continuously gather feedback from users, monitor performance in different markets, and identify opportunities for improvement. This ongoing cycle of refinement often leads to product line extensions, improved formulations, or entirely new product categories.

The pool industry's seasonal nature adds another complexity layer, as launch timing can significantly impact product adoption. Products introduced at the beginning of pool season have the best chance of gaining market traction, while mid-season launches may need to wait a full year to demonstrate their potential.

The Future of Pool Chemical Innovation

Looking ahead, several trends are shaping the future of pool chemical development. Environmental sustainability continues to drive innovation toward more eco-friendly formulations. Smart pool technology is creating opportunities for chemicals designed to work with automated monitoring and dosing systems.

Consumer preferences for simpler, more convenient products are pushing manufacturers to develop solutions that require less frequent application or complex mixing procedures. The growth of saltwater pools and alternative sanitization systems is creating demand for specialized chemical treatments tailored to these systems.

As Edgar noted during the podcast discussion about visiting manufacturing facilities, seeing the complexity behind seemingly simple products changes your appreciation for the work involved. The same principle applies to chemical development – understanding the journey from concept to shelf helps explain why innovation takes time and why quality products command premium prices.

Because it's that machine is half a million dollars and this is what it costs for this. And this is what and you look and there's like six machines and you're like, hold it. But then you see the work that has to go in it and even plastic, right?

— Edgar De Jesus, Pool Nation Podcast

The pool chemical industry continues to evolve, driven by changing regulations, environmental concerns, and user demands for better performance and convenience. Companies like BioLab invest heavily in research and development because they understand that tomorrow's market leaders will be those who can successfully navigate the complex journey from napkin sketch to store shelf while delivering real value to pool professionals and homeowners alike.

Episode Chapters

• 00:00 Introduction and Show Updates
• 05:30 Vegas Road Trip Planning
• 12:15 Pool Pro Challenge and Awards Update
• 18:45 Conference Details and Registration
• 25:00 Introduction to BioLab Guests
• 28:30 Chemical Development Deep Dive Begins