From Foam to Function: How Smarter Packaging Unlocked Greater Supply Chain Efficiency for Traeger Grills

The original wood pellet grills, Traeger Grills are cherished by legions of barbecue purists for precision and durability. Their prior packaging? Not so much. Here’s how that changed—and what it unlocked.

The Challenge

Low-quality materials weren't living up to Traeger's brand

Traeger’s previous packaging relied heavily on foam, plastic, and inconsistent materials sourced by Original Equipment Manufacturers (OEMs).

Not only did this affect the unboxing experience, but it also led to higher costs, inefficiencies, and compliance challenges—especially when selling through Amazon.

Traeger sought to revamp their packaging for a superior customer experience, cost savings, and sustainability.

Problems to tackle

Due to low-cost, low-quality materials, Traeger faced significant hurdles in controlling their packaging process and delivering a satisfying customer experience.

Low-Quality Foam and Plastic

were creating unnecessary waste.

Lack of Cohesive Design

was detracting from Traeger’s premium brand perception.

Supply Chain Inconsistencies

were making it hard to maintain quality.

Amazon Compliance Challenges

including requiring a second box were doubling costs and complicating logistics.

Our Approach

Redesigning packaging to delight customers and reduce waste

Trillora’s packaging engineers and designers focused on eliminating foam while maximizing protection and efficiency.

The new solution featured:

High-performance corrugated inserts to replace EPS foam, providing superior impact absorption.
Thoughtful, brand-enhancing design elements, including printed graphics inside the box, offering a second life as a playhouse for kids.
Built-in bottle holders to elevate the customer experience with added convenience during assembly.
Ergonomic and supply chain-friendly packaging, ensuring efficient transport, storage, and assembly.

Over several months, the new packaging underwent rigorous ISTA testing (1A, 3A, 3B, and 6A) to ensure durability and compliance while maintaining aesthetic appeal.

The changes created a whole new unboxing experience. Traeger came away with an optimized design that was scalable across multiple grill lines and met all of their objectives.

Traeger Grills_Playhouse

Speak to a packaging expert

Traeger has been able to leverage Trillora’s design expertise to supplement our constrained resources as it relates to packaging engineering. This has proven invaluable in improving product design and overall product quality.

– Trevor Rametta, Director of Global Sourcing, Traeger Grills

The Results

A sustainable packaging transformation

The new packaging was a resounding success, achieving all of Traeger’s key goals:

156,000 pounds of non-biodegradable plastic replaced with sustainable corrugated materials in one year.
ISTA-certified packaging that met stringent durability and safety standards.
Enhanced customer experience through an engaging, well-organized unboxing process.
Cost-effective design that aligned with Traeger’s budget and still complied with Amazon requirements.
Scalable solution that Trillora is now expanding across Traeger’s full product portfolio.

Workers assemble fun new Traeger Grills packaging

CONTACT

Ready to design packaging that works for you?

If you’re shipping from factories in Asia and are struggling with costs and inefficiencies driven by your current packaging, Trillora Packaging Solutions can help. We’ve worked with numerous brands to improve the customer experience and reduce damage, shipping costs, and packaging headaches.

Click the button below to reach out to our team today.

Get in touch

Trillora_Packaging Design_How We Stand Apart