What was holding production back before FlexPak?

The knockboxes filled the cones, but then we had to manually pack every single pre-roll with a pen. With eight to ten people working the whole day, 8,000 was our maximum.

How quickly did the team begin producing?

We were running the machine on the first day. It took one to two weeks to dial in the weight ranges and get every operator to full speed. We started around 10,000 per day, and then we reached 20,000.

What did the added capacity change for the business?

We finally had stock on the shelf and could get ahead of orders. Instead of telling customers we could only promise a limited quantity, we had product ready to sell. It roughly tripled our pre-roll business.

How did you maintain tight weights at higher volume?

Start with a consistent farm and build a consistent grinding process. If the grind changes, the weights change. Once we controlled those upstream steps, we held about a 0.04 g margin while producing 20,000.

What would you tell another operator comparing equipment?

If you're looking to save on labor, FlexPak is the way to go. Look at the price point against the output. We made our money back within the first sales order, and the system allowed those other employees to work on products that also make us money.

Case StudiesModern Distribution

High-Volume Hemp Operator Case Study

Modern Distribution · Operations Manager

From 8,000 a Day With 8–10 People
to 40,000 With Four Operators

How Modern Distribution replaced a labor-heavy knockbox workflow, cleared its production backlog and built a three-machine FlexPak operation with capacity for nearly 50,000 pre-rolls in a day.

"Stock on the shelf. We were finally getting ahead of orders."Markie Davis · Operations Manager, Modern Distribution

40,000Expected daily output with two FlexPak machines

≈47,000Client-reported record day

2 PEOPLECore crew per machine at full-speed production

1 WEEKReported equipment payback on the first major order

More Case Studies

FlexPak Commercial Solution

FlexPak Max — Built for this kind of output.

See how the FlexPak Max fits your operation. USA-built, no mandatory service contract, lifetime technical support.

See Machine Specs

From 8,000 a Day With 8–10 People to 40,000 With Four Operators

More Case Studies

Surterra Wellness — From 15,000 to 50,000 Pre-Rolls a Day

Perpetual — From a 40K Low Back to 140K Pre-Rolls a Month

Rebel Roots Farms — From a 5,000-Unit Daily Struggle to 2 Million Pre-Rolls a Month

My Friend Processing — From 2,000 Finished Pre-Rolls a Day to 22,000 Retail-Ready—With the Same Four-Person Crew

FlexPak Max — Built for this kind of output.

From 8,000 a Day With 8–10 People
to 40,000 With Four Operators