EcoTab Smart Chlorine Dispenser
Reimagining Pool Maintenance Through IoT Innovation
YEAR
2021
CLIENT
EXPERTISE
Electronic design
Firmware development
Testing & Qualification
Mass Production
Project Overview
When ioPool approached Tektos Design in 2021, they had a bold vision: to transform pool maintenance from a daily chore into an automated, eco-friendly experience. Over twelve months, we partnered with them to bring the EcoTab to life—a solar-powered smart chlorine dispenser that would redefine how pool owners maintain their water quality.
Our collaboration spanned the entire product lifecycle, from initial electronic design through firmware development, rigorous testing, and finally to mass production. The result was a market-ready IoT device that makes pool ownership simpler, more sustainable, and more reliable.
Pool ownership comes with a hidden burden that most people don't anticipate. Every day, pool owners face the tedious task of testing water chemistry, calculating the right amount of chlorine to add, and manually dispensing chemicals. Miss a day, and the water can become unsafe. Add too much, and you've wasted money while creating an unpleasant swimming experience with stinging eyes and harsh chemical odors.
The consequences of inconsistent pool maintenance extend beyond inconvenience. Under-chlorination creates health risks as bacteria multiply in untreated water. Over-chlorination wastes expensive chemicals and damages pool equipment over time. Traditional automated systems exist, but they're power-hungry, expensive to operate, and typically work only with specific pool configurations.
ioPool saw an opportunity to solve these problems through smart technology. They envisioned a device that would float in any pool, automatically maintaining optimal chlorine levels without human intervention. The device would need to be intelligent enough to adapt to different pool sizes and environmental conditions, yet simple enough for any homeowner to install and use. The environmental aspect was crucial—rather than adding another device to a home's electrical load, they wanted something that operated entirely on solar power.
Turning this vision into reality presented formidable engineering challenges. We needed to design electronics that could survive constant exposure to chlorine, intense UV radiation, temperature extremes, and water. Power management posed another significant challenge—solar energy is intermittent by nature, yet the device needed to operate reliably year-round. The dispensing mechanism had to be precise enough to maintain safe chlorine levels without over-treating the water. Finally, the device would sit outside, potentially far from WiFi routers, surrounded by water that interferes with radio signals, yet homeowners would expect reliable real-time monitoring through their smartphones.
The Challenge
Our Approach
We began by immersing ourselves in the world of pool ownership, interviewing dozens of pool owners, maintenance professionals, and retailers. These conversations revealed insights that shaped our entire design approach.
Our industrial design team explored multiple form factors, settling on a streamlined design that balances stability with easy tablet access. We chose UV-resistant, chlorine-proof polymers and selected energy-efficient components, a low-power microcontroller paired with a solar charging circuit optimized for even low-light conditions.
The heart of EcoTab's innovation lies in its firmware. We developed adaptive algorithms that learn each pool's unique characteristics over time. The device observes chlorine dissipation rates, temperature effects, and usage patterns, creating a customized dispensing schedule that becomes increasingly accurate.
Power management required creative problem-solving. We implemented a multi-tiered sleep system that degrades non-essential features during extended cloudy periods while ensuring chlorine delivery continues uninterrupted. Safety was paramount; we programmed multiple fail-safe mechanisms that prevent over-dispensing under any circumstance.
The first prototypes were humbling. Feeding mechanisms jammed, buoyancy caused tilting, but each failure drove the next iteration. By the third generation, we had something ready for real-world testing.
We deployed units across different climates, from Arizona's intense heat to Seattle's cloudy conditions, testing in traditional chlorine pools, saltwater systems, spas, and commercial installations. Environmental testing subjected units to accelerated aging, UV exposure, and temperature extremes. Field testing provided the most valuable insights, with real users revealing edge cases that informed algorithm refinements. The data was remarkable; units maintained chlorine levels within target range over ninety percent of the time.
As testing validated our design, we shifted to regulatory compliance and manufacturing preparation. We optimized the PCB layout for automated assembly, reduced the bill of materials, and established quality control checkpoints throughout production. Through design refinements and supplier negotiations, we reduced manufacturing costs significantly while maintaining ioPool's quality standards.
The Solution
The final EcoTab embodies the balance of sophisticated technology and effortless user experience. When a pool owner places the device in their water, it begins working immediately. The smart dispensing system continuously monitors conditions and releases precise amounts of chlorine based on real-time needs. Unlike timer-based systems that dispense blindly according to a fixed schedule, EcoTab adapts to what's actually happening in the pool.
The solar panel harvests energy throughout the day, storing excess power in the onboard battery. This means the device operates with zero electrical costs and no need for outlet access or battery changes. Even during extended periods of cloudy weather, the optimized power management allows the device to continue functioning for days without sunlight.
Through the mobile app, pool owners gain unprecedented insight into their water quality. They can see real-time chlorine levels, track historical trends, and receive proactive notifications when maintenance is needed. Universal compatibility was a design priority from the start—whether someone has a small above-ground pool, a large in-ground installation, a spa, or a hot tub, EcoTab adapts. It works equally well in traditional chlorine pools and saltwater systems across a wide temperature range.
Durability engineering ensures that EcoTab withstands years of outdoor exposure. The UV-resistant housing maintains its appearance and integrity through countless hours of sun exposure, while chemical-resistant materials prevent degradation from constant chlorine contact. When it's time to add chlorine tablets, the tool-free compartment access makes the process quick and simple.
The Results
The numbers tell a compelling story. In real-world use, EcoTab maintains target chlorine levels with remarkable consistency. Pool owners using the device report dramatic reductions in the time they spend on maintenance—what once required daily attention now needs only occasional tablet refills. The precision dispensing eliminates the over-chlorination that plagues manual methods, reducing chemical waste substantially while saving users money on chlorine costs.
From a business perspective, the launch exceeded expectations. ioPool successfully brought the product to market and achieved strong customer adoption. User reviews consistently highlight the convenience and reliability, with satisfaction ratings reflecting that we'd solved a real problem in a meaningful way.
The environmental impact aligns with ioPool's original vision. Every EcoTab in operation represents zero ongoing electricity consumption and a significant reduction in excess chlorine entering water systems. Pool owners who once dreaded maintenance now describe it as effortless, and many share that they can travel with confidence knowing their pool water will be perfect when they return.
What We Learned
Early engagement with end users proved invaluable. The insights from those initial interviews shaped decisions throughout the project, from feature prioritization to interface design. The modular design philosophy allowed rapid iteration during development; when field testing revealed issues or opportunities for improvement, we could modify specific subsystems without redesigning the entire product.
Close collaboration with manufacturing partners from the design phase paid dividends during production ramp-up. Rather than throwing a design over the wall and hoping for the best, we involved manufacturing engineers in design reviews. Their input on assembly challenges, material availability, and cost drivers influenced our design decisions early when changes were easy and inexpensive.
Several technical breakthroughs emerged from this project. The chlorine resistance challenge required multiple approaches before we found success by combining protective coatings with inherently resistant materials. Power management during cloudy winters initially tested our assumptions about solar viability, but software-driven optimizations maintained functionality while keeping hardware costs in check. Post-launch firmware updates have added capabilities we didn't envision during initial development, creating a virtuous cycle where the product continues improving based on real-world experience.
Our Expertise in Action
The EcoTab project exemplifies Tektos Design's comprehensive capabilities across the entire product development lifecycle. We began with a client's vision and market insight, then applied our engineering expertise to solve complex technical challenges spanning electronic design for harsh environments, embedded firmware development with adaptive algorithms, and IoT integration with cloud services and mobile applications.
Our ability to navigate the complete journey from concept to mass production meant ioPool had a single partner accountable for outcomes. When challenges arose, we could quickly mobilize expertise across disciplines to find solutions. The integration of design, engineering, testing, and manufacturing knowledge under one roof accelerated development and reduced risk.
Most importantly, the EcoTab demonstrates our user-centric design philosophy. We created a product that solves real problems elegantly, where sophisticated technology operates invisibly behind a simple experience. Pool owners don't need to understand adaptive algorithms or power management—they just enjoy crystal-clear water without the maintenance burden.
Ready to Turn Your Vision into Reality?
Whether you're developing smart home devices, IoT products, or innovative hardware solutions that need to withstand challenging environments, Tektos Design brings the expertise to transform concepts into market-ready products.