
Building a Sports Nutrition Brand on a $30K House Deposit - Maple Movement Founder Dan McDonnell
Dan McDonnell was a pro triathlete with a wrecked gut. After a bacterial infection forced him out of racing, he started fuelling his training with maple syrup and a pinch of salt, and had no gut issues. Two years later, Maple Movement makes all-natural maple energy gels with three ingredients or fewer, used by HYROX athletes, triathletes, runners and NRL and AFL teams. Daniel, who still works as an aviation firefighter, talks with Ryan about putting their $30K house deposit into the business, and how product issues cost them more than $50K in written-off stock and refunds. He explains how handing out 5,000 gels at a single HYROX event, guerrilla-style, beat paying for expo stands, and how LSKD lets them sample for free in its event hubs. Plus, building a 120-person race team and a creator program, growing into 99 Bikes and New Zealand, and why runners keep telling him they hate thick gels. In this episode Pre-chat: getting back into training, and setting priorities as family, then business, then sport Two years in: growth in national retail, Black Friday plans and a tough few months What Maple Movement is: natural maple energy gels with three ingredients or fewer Maple syrup 101: a four-week tapping season, why Canada produces around 90% of the world's supply, and why Maple Movement uses a light grade Why maple syrup has to be pasteurised every time it's repackaged (it isn't antibacterial like honey) The product issues: fermenting sachets, overcooked syrup, maple sugar "pebbles", leaky sachets, and a June batch that swelled up like basketballs Writing off $40K of stock, more than $50K in total, and sending a full box by express to anyone affected Daniel's background: dropping out of engineering, then eight years as an aviation firefighter on Hamilton Island and in Cairns The origin story: years of gut problems on traditional gels, an H. pylori infection, and a pro debut in Taupō fuelled by maple syrup in a bike bottle Asking US brand UnTapped for Australian distribution rights and being turned down ("What's your distribution network like?") The $30K house deposit: spent on company setup, legal and trademarks before they had any maple, plus naming it "Raw Nutrition" first A supplement workshop, a logo designer found through Daniel's sister, and doing all marketing in house Organic content: Ella growing the Instagram to 21,000 followers in two years, and hiring help so she has time to create Why expos at Mooloolaba and an IRONMAN 70.3 lost money, standing next to eight to ten other nutrition brands The HYROX play: handing out 5,000 gels at the door, three or four reels a day, and racing the event too How the LSKD partnership started, and sampling for free in its HYROX hubs Race team vs creator program: 120 athletes across competitive and elite tiers, and a creator program to rely less on Meta ads Ryan's tip: the Brand Pay episode and "customer media" Being turned down by UnTapped again, this time for help with the product issues What's next: national wholesale, New Zealand with a national distributor, and maybe Asia as HYROX grows there Coles and Woolworths? Not for now. E-commerce is the engine that powers wholesale Events in the AI era: why meeting customers in person matters more than ever, and why four-day expos aren't sustainable with a newborn Handing over events: training Daniel's younger brother, "a sleazy car salesman", to tell the brand story "I hate thick gels": what customers say at expos, and why Maple Movement chose a runny texture Mentors: quitting his triathlon coach to pay for a business mentor, Dan Roberts, and the team of four Handling product issues the LSKD way: Adam Sullivan's logo misprint














