What did production look like before FlexPak?

We were trying everything—knockboxes, reefer heads and other devices. We were making about 500–600 an hour, around 5,000–6,000 a day, with roughly 10 people involved. Closing and QC were inconsistent, and nothing was truly scalable.

What changed when the first FlexPak arrived?

Overnight, one machine with three or four people could do about 5,000 an hour and 20,000–30,000 in a day. We went from struggling with our weekly target to completing 50,000 in about three production days.

How did you keep five machines moving?

The philosophy was to prioritize loaded plates so the operator never stopped producing. We had people preloading cones while others closed. As soon as one plate came out, the next went into the machine.

How important were material preparation and quality control?

The machine gives you the control, but you still have to grind, sift, clean and dial in the density for your material. Once that process is set, we were above 90% on weight and inspection—usually closer to 97%.

What would you tell a smaller operator deciding whether to invest?

The difference becomes labor, consistency and getting your time back. You can finish a 10,000-unit order without building an entire production floor around it. When you know the product will come out right, you're not wasting material or doing the work twice.

Case StudiesRebel Roots Farms

MSO (Multi-State Operator) Case Study

Rebel Roots Farms · Operator and Manager

From a 5,000-Unit Daily Struggle
to 2 Million Pre-Rolls a Month

How Rebel Roots Farms — a multi-state operator (MSO) — turned one FlexPak into a five-machine production system capable of supporting one of the industry's highest-volume pre-roll operations.

"We do 2 million a month easily using FlexPak."Dean Smith · Operator and Manager, Rebel Roots Farms (MSO)

2 MILLIONPre-rolls produced per month at peak scale

20K–30KClient-reported daily output per machine

90%+Weight and inspection pass rate—often near 97%

1-2 WKSEstimated equipment payback, depending on order and margin

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 a 5,000-Unit Daily Struggle to 2 Million Pre-Rolls a Month

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

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

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

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 a 5,000-Unit Daily Struggle
to 2 Million Pre-Rolls a Month