What was production like before FlexPak?

We had four or five knockboxes, then an ActionPac RollMaster 420, and then the Eight-Channel JuanaRoll. The biggest issues were labor, downtime and consistency. With the JuanaRoll, there were only a few times we hit 15,000 in a 10-hour day—and that was still with five or six people.

What changed after the workflow consultation?

We went over the workflow and the timing for every stage. I took the notes straight back to the team, and we added a fourth cone plate. Once they got the feel for it, they went from about 20 trays in a day to 45. The stress started coming down because we knew we could hit the numbers.

What did the full two-line setup produce?

With one box, four plates and four technicians, each line was producing about 24,000 to 25,000 in a 10-hour shift. Adding the second line doubled it. We were hitting 48,000 to 50,000 pre-rolls in a single 10-hour day.

How did finished quality and waste compare?

I like how firm and almost perfect the pre-roll comes out. There's very minimal waste—less than 1% rejects for us. And when there was a reject, it usually came back to how the material was prepared, not the machine.

What would you tell an operator who is still hesitant?

Just buy it. Trust it, man. Look at what you're using, look at where you want to go, and understand that you can alleviate a lot of stress and problems through this machine. You're going to hit your numbers.

Case StudiesSurterra Wellness

MSO (Multi-State Operator) Case Study

Surterra Wellness · Operations Manager

From 15,000 to 50,000
Pre-Rolls a Day

How the vertically integrated Florida operation of a large multi-state operator (MSO) replaced high-downtime equipment with two repeatable FlexPak production lines built to supply 45 dispensaries.

"It's easy to speak to because it works."David B. · Operations Manager, Parallel (MSO)

48–50KPre-rolls in one 10-hour day

25–27KAverage output per FlexPak line

4Technicians per production line

<1%Reported reject rate

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 15,000 to 50,000 Pre-Rolls a Day

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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

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 15,000 to 50,000
Pre-Rolls a Day