Solving Internal Structure Risks in Gas Water Heaters: An ODM Case Study with a Leading North American Brand | Greaidea Gas Hobs & Gas Water Heaters Manufacturer Cases

In today's highly competitive home appliance market, long-term brand growth is no longer driven by price alone, but by product reliability, structural safety, and the ability to respond quickly to real market feedback.

For established appliance brands, even minor internal design issues—such as valve stability or power supply reliability—can lead to customer complaints, distributor hesitation, and brand trust erosion over time.

This case study shares how Greaidea, as an experienced ODM & OEM gas water heater manufacturer, worked closely with a long-term North American brand partner to identify hidden structural risks, redesign critical internal components, and deliver not only a more reliable product, but also stronger market competitiveness and sales confidence.

Case Study: Solving Internal Structure Issues in Gas Water Heaters for a Leading North American Brand

Our customer is a well-established home appliance brand in North America, operating in a small but mature national market.

With decades of local market experience, the brand has built a strong distribution network and already occupies a significant share of the national appliance market, especially in gas water heaters.

As a long-term partner, Greaidea has provided ODM & OEM manufacturing services to this brand for many years. Throughout the cooperation, both teams maintained continuous communication on sales performance, after-sales feedback, and real user complaints, allowing product optimization to be driven by actual market data rather than assumptions.

Challenge｜The Core Problems Faced by Customers

As the market matured and consumer expectations increased, the customer raised concerns about internal structure reliability in their gas water heaters.

The key challenges included:

Valve body connection risk

The original press-type valve body structure required high installation precision. If not installed perfectly during production, or after long-term transportation vibration, the connection could loosen. Over time, this could cause water leakage, leading to customer complaints and warranty pressure.

Battery durability issue

End users reported frequent battery replacement, affecting user experience. In some regions, battery availability and cost became a practical concern

Market differentiation pressure

The customer wanted to launch an upgraded model that truly solved existing industry pain points. The goal was to stand out from competitors, strengthen consumer trust, and reinforce brand positioning. This was not a simple component replacement request, but a system-level product iteration combining engineering reliability, user experience, and market competitiveness.

Action｜Greaidea's Systematic Solutions

1. Internal Structure Redesign by Engineering Team

After a full internal analysis, Greaidea engineers redesigned the valve body connection:

Replaced the clamp-type valve body with a threaded valve body structure

Advantages of the threaded design: More stable mechanical connection. Easier and more consistent installation for production workers. Significantly reduced risk of loosening during transportation or long-term use

Result: Leakage risks were structurally eliminated, not just controlled

This improvement enhanced production consistency, long-term durability, and quality stability, which is critical for large-scale gas water heater OEM/ODM manufacturing.

2. Power Supply Upgrade for Better User Experience

To address the battery issue, Greaidea proposed a dual power solution:

Added a power adapter option, allowing: Battery + power adapter interchangeable use. Continued operation even when batteries are depleted.

Reduce the frequency of battery replacement, improve convenience for end-users, and adapt to different market preferences and usage scenarios.

This solution directly responded to real consumer feedback, improving product practicality rather than adding unnecessary features.

3. Beyond Manufacturing: Full Marketing & Sales Support

Beyond product engineering and manufacturing, Greaidea supported the customer with end-to-end marketing and sales enablement, ensuring the upgraded product could be launched and promoted efficiently in the market.

Instead of requiring the brand to coordinate multiple external partners, Greaidea handled packaging and outer carton design in-house, eliminating the need for third-party designers and significantly reducing coordination costs. At the same time, the team developed customized POP materials, including product posters that clearly communicated the upgraded internal structure, as well as short videos and visual assets tailored for distributors and retail channels.To further support sales teams, complex technical improvements were translated into clear, consumer-friendly selling points, making it easier for distributors to explain the product's advantages.

This integrated ODM service model not only shortened the customer's time-to-market, but also reduced internal workload, allowing the brand to focus more on channel expansion and market growth.

Greaidea delivers Quality+ Complete Gas Water Heater Solutions

Result｜Greaidea's Final Results and Market Feedback

After the upgraded gas water heater was launched:

Customer complaints dropped significantly

Leakage-related issues were largely eliminated

Power supply complaints reduced due to flexible usage options

Market differentiation achieved

While competitors still faced similar structural issues, this brand had already moved ahead

Brand reputation strengthened

Positive word-of-mouth among distributors and end users

Increased trust from retail partners

Sales performance improved

Higher reorder rates

More distributors willing to promote the upgraded model

From the customer's perspective, cooperation with Greaidea became:

Easier — fewer coordination costs

Faster — one-stop solution from engineering to marketing

More reliable — a partner that proactively solves problems

Why This Case Matters for Global Brands

This case clearly demonstrates that true product competitiveness is built on solving real, market-proven problems rather than simply adding new features.

For brands targeting North America, Latin America, and other regulated or highly competitive markets, long-term success depends on working with a partner who deeply understands internal structure safety, long-term product reliability, end-user experience, and how technical improvements should be communicated to the market.

As an experienced ODM & OEM gas water heater manufacturer with 25 years of industry expertise, Greaidea combines engineering capability, manufacturing stability, and commercial insight to support brands beyond production alone. By integrating product development, quality control, and market-facing support, Greaidea helps global brands reduce risk, accelerate growth, and build sustainable competitive advantages in their local markets.

Let's Build Your Next Market-Ready Solution

If you are looking for a customized gas water heater solution, whether for:

internal structure optimization

ODM & OEM manufacturing

product upgrade for mature markets

or integrated engineering + marketing support

Contact Greaidea today to discuss a tailor-made solution designed around your market, your users, and your brand vision. We don't just manufacture products — we help brands win markets. Email: sales@greaidea.com Whatsapp:+86 13380262303