From Basement Beginnings to a Thriving Brand: The Hilltop Packs Story
Tucked away in the rolling hills of Waynesburg, Pennsylvania, Hilltop Packs began not in a flashy storefront or a big-box warehouse, but in the modest basement of the McMillen family home. It started with a simple idea: create quality and highly customizable gear for backpackers, made by people who live and breathe adventure.
Back in 2019, Ben McMillen—a professional photographer and print shop owner turned hiking enthusiast—found himself surprised with the lack of ultralight gear options that balanced functionality and personality. So, like many great ventures before him, he decided to make his own. Armed with a sewing machine, a few yards of Dyneema fabric, the knowledge of how to print on unique materials, mixed with a lifelong entrepreneurial spirit, Ben began crafting custom ultralight and ultra-custom backpacking gear in his basement. What started as a fun side project for friends and family quickly drew attention from hikers across the country and eventually around the world.
With the help of social media and youtube, the news spread fast. Hilltop Packs gained a reputation not just for the quality of its handmade gear—like ultralight backpacks, food bags, and accessories—but also for its ability to personalize those items with custom prints, photographs, trail names and logos. It was gear that could tell a story with a photo of loved ones and past adventures. Gear that would no doubt inspire you to get outside.
As the demand for Hilltop Packs grew, what began as a solo effort quickly turned into a family affair. Ben’s wife and daughters (even their young son pretended to help) soon jumped in to help manage the increasing number of orders, lending their hands and hearts to the business. What was once a quiet creative space in the corner of the basement transformed into a buzzing hub of activity.
To keep up with production, they added more sewing machines, cutting tables, and workstations—each one carefully placed to maximize their limited space. Every square foot of the downstairs was eventually claimed by fabric rolls, gear prototypes, custom prints, and the steady hum of sewing machines. The family’s basement no longer resembled a typical home—it had become a full-fledged gear workshop.
Despite the tight quarters, the spirit of collaboration and creativity never wavered. In fact, the basement’s transformation marked a turning point for Hilltop Packs. It was clear that this wasn’t just a side project anymore—it was becoming something much bigger. That energy, rooted in family support and hands-on craftsmanship, would carry the brand into its next exciting chapter.
As demand grew, so did the shop location and team members. What was once a one-man operation evolved into a small, dedicated crew of makers, each one committed to craftsmanship and customer service. Hilltop Packs moved out of the basement and into their first rented space in 2020 which they quickly outgrew. Just nine months later they moved again to a much larger commercial location, where they could scale their operations without sacrificing the hands-on quality that made them popular in the first place.
Today, Hilltop Packs ships gear all over the world, and their reach extends far beyond their Appalachian roots. They’ve even expanded into other ventures—like Hilltop Packs Coffee, a coffee roastery born from the same passion that fueled the original brand.
But despite their rapid growth, the heart of Hilltop Packs remains unchanged: a love for the outdoors, a dedication to quality, and a belief that even the biggest journeys can start in the smallest places—like a basement in Waynesburg, PA.
